La pressofusione semplice è una procedura semplificata, tecnologia di formatura dei metalli a bassa barriera che colma il divario tra la pressofusione di livello industriale e la tradizionale fusione a gravità. A differenza della pressofusione ad alta pressione (che richiede macchine da un milione di dollari), Si basa su riempimento assistito per gravità + pressurizzazione manuale/leggera per produrre parti funzionali, rendendolo ideale per piccole officine, Sviluppo del prototipo, progetti educativi, o manutenzione di emergenza. Anche se non può eguagliare i processi industriali in termini di precisione o velocità, il suo basso costo, flessibilità, e configurazione rapida (velocemente come 2 ore dalla preparazione dello stampo alla prima parte) renderlo insostituibile per scenari specifici. Questo articolo analizza sistematicamente i suoi principi fondamentali, implementazione passo dopo passo, strategie di risoluzione dei problemi, and practical applications to help you master this accessible technology.
1. Definizione principale & Key Characteristics of Simple Die Casting
To avoid confusion with industrial die casting, it’s critical to clarify what simple die casting is—and isn’t. Questa sezione utilizza a 总分结构 con i termini chiave evidenziati per chiarezza.
1.1 Definizione fondamentale
Simple die casting is a low-cost metal-forming process that uses gravity to fill mold cavities with molten metal E manual/light mechanical pressure (PER ESEMPIO., modified screw jacks, lever systems) to reduce porosity and ensure dimensional stability. It eliminates the need for industrial-grade hydraulic systems, complex cooling circuits, or automated feeding—relying instead on basic tools (small furnaces, hand-operated presses) and simplified molds.
Its core goal is not mass production, Ma rapid validation: creating functional parts to test designs, repair equipment, or demonstrate casting principles—all at a fraction of the cost of industrial processes.
1.2 Caratteristiche chiave (contro. Industrial Die Casting)
The table below highlights the critical differences between simple and industrial die casting to set realistic expectations:
| Caratteristica | Simple Die Casting | Industrial Die Casting |
| Pressure Source | Manual/light mechanical (5-50 kn; 0.5-5 MPA) | Hydraulic/pneumatic (100-50,000 kn; 10-175 MPA) |
| Costo dell'attrezzatura | \(500-\)5,000 (small furnace, modified press, basic molds) | \(500,000-\)5M (high-pressure machines, muore di precisione, automazione) |
| Tempo di configurazione | 1-2 ore (mold prep + Fusione del materiale) | 1-3 mesi (die machining + Calibrazione della macchina) |
| Tolerance Grade | IT12-IT14 (±0.5-1.0 mm for small parts) | IT8-IT11 (±0,05-0,2mm) |
| Rugosità superficiale | Ra 6.3-12.5 µm (requires sanding for smoothness) | Ra 1.6-3.2 µm (qualità quasi finale) |
| Batch Suitability | 1-100 parts/run (piccolo batch, on-demand) | 10,000+ parts/run (produzione di massa) |
2. Step-by-Step Implementation: From Preparation to Post-Processing
Simple die casting’s strength lies in its simplicity—but success still requires following a structured workflow. Questa sezione utilizza a linear 叙述 structure with specific parameters and tool recommendations.
2.1 Fase 1: Materiale & Preparazione degli strumenti (Critico per il successo)
The right materials and tools prevent 80% of common defects (PER ESEMPIO., sticking, porosità). Di seguito è riportato un checklist of essentials with practical tips:
| Categoria | Items | Specifiche & Suggerimenti |
| Leghe di metallo | – Zinc-based alloys (Carichi 3, melting point 380-385°C)- Aluminum-silicon alloys (ADC12, melting point 570-620°C)- Wood’s metal (Melt basso, 70°C—for educational demos) | – Avoid high-melt metals (ghisa, acciaio): Require industrial furnaces.- Recycle waste aluminum (PER ESEMPIO., soda cans) for practice—cost-effective but clean thoroughly (remove paint/plastic). |
| Mold Materials | – Steel plates (≥20mm thick, A36 or 45# acciaio)- Cast iron (better heat retention than steel, lower thermal expansion) | – Use wire cutting to machine cavities (ensures Ra ≤6.3 μm for easy demolding).- Drill 2-3mm diameter exhaust holes at the cavity’s highest point—critical for reducing porosity. |
| Utensili | – Fusione: Small electric furnace (500-1000W) or coke-fired crucible- Pressurizzazione: Modified screw jack (5-10 Capacità kn) or lever press- Sicurezza: Heat-resistant gloves, face shield, dry powder fire extinguisher | – Avoid propane torches for melting: Riscaldare in modo non uniforme, increasing oxide formation.- Wrap the crucible in asbestos tape to retain heat (reduces re-melting time). |
| Auxiliaries | – Release agent: Graphite powder + machine oil (1:3 rapporto) or zinc oxide solution- Pulizia: Wire brushes (for mold oxide removal), acetone (for degreasing) | – Test release agent on a scrap mold first: Too thick causes surface defects; too thin leads to sticking. |
2.2 Fase 2: Mold Pretreatment (Avoids Sticking & Restringimento)
Mold preparation is the most overlooked step—skimping here causes 60% of simple die casting failures. Segui questi tre passaggi:
- Thorough Cleaning: Use a wire brush to remove oxide scales from the cavity, then wipe with acetone to eliminate oil stains. Even a small amount of oil burns during casting, creating porosity.
- Preriscaldare: Heat the mold to 150-200°C (use a propane torch with a temperature gun for monitoring). Cold molds cause molten metal to solidify too fast, leading to shrinkage and underfilling.
- Applicazione dell'agente di rilascio: Spray or brush a thin layer of release agent (0.1-0.2mm di spessore) on the cavity surface. Lascialo asciugare per 2-3 minutes—this forms a barrier between the metal and mold, prevenire l'adesione.
2.3 Fase 3: Fusione & Versare (Temperatura di controllo & Velocità)
The goal here is to get molten metal into the mold smoothly, with minimal oxidation:
- Melting Temperature Control:
- Zinc alloys (Carichi 3): 400-420° C. (look for a bright, clear liquid—no dark oxides).
- Leghe di alluminio (ADC12): 720-760° C. (liquid turns bright silver; stir with a steel rod to remove floating impurities).
- Use a digital thermometer to monitor temperature—overheating (PER ESEMPIO., >800°C for aluminum) increases oxide formation; underheating causes poor fluidity.
- Tecnica di versamento:
- Tilt the crucible and pour the metal slowly along the mold’s side wall (not directly into the cavity). This avoids splashing (which creates air bubbles) and protects the mold’s core (Se usato).
- Stop pouring when the metal level reaches the overflow groove (leave 1-2mm space for shrinkage). Overfilling causes flash (materiale in eccesso) that’s hard to trim.
2.4 Fase 4: Pressurizzazione & Raffreddamento (Reduces Porosity)
Simple die casting’s light pressure is key to improving part quality—follow these rules:
- Timing: Apply pressure immediately after pouring (entro 5-10 Secondi). Delays let the metal start solidifying, making pressure ineffective.
- Applicazione di pressione: Use a screw jack to apply 5-10 kN of force (adjust based on part size: 5 kN for small parts <100G, 10 kN for larger parts <500G). Maintain pressure for 5-10 minutes—this compresses air gaps and ensures the metal fills all cavity details.
- Raffreddamento: Let the part cool under pressure until the mold’s surface temperature drops to <100° C. (touchable with gloves). Sudden pressure release causes the part to expand, creating internal cracks.
2.5 Fase 5: Sformatura & Post-elaborazione (Finishes the Part)
Gentle demolding and basic finishing turn raw castings into functional parts:
- Sformatura: Tap the mold’s back with a soft hammer (brass or rubber) to loosen the part. Se si attacca, insert a plastic wedge (not metal—avoids mold damage) into the parting line and gently pry.
- Taglio: Use a hacksaw or angle grinder to cut off the gate (the metal channel connecting the part to the overflow). File sharp edges with 120# carta vetrata.
- Levigazione: Sand the part with 120# → 240# → 400# sandpaper to reduce roughness from Ra 12.5 μm a RA 6.3 µm. Per parti decorative, apply a metal polish (PER ESEMPIO., Brasso) for a shine.
- Sollievo da stress (Opzionale): Heat small aluminum parts to 200-250°C for 30 minuti, then let them cool naturally. This eliminates internal stress caused by uneven cooling.
3. Problemi comuni & Soluzioni comprovate (Troubleshooting Guide)
Even with careful preparation, defects can occur. La tabella seguente utilizza a problem-cause-solution structure to help you fix issues quickly:
| Tipo di difetto | Cause principali | Soluzioni passo dopo passo |
| Porosità (Honeycomb Holes) | 1. Scarso scarico (blocked 2-3mm holes)2. Fast pouring (traps air)3. Mold too cold (causes rapid solidification) | 1. Ream exhaust holes with a 2.5mm drill bit to remove blockages.2. Slow pouring speed to 0.1-0.2 l/min (use a small ladle to control flow).3. Increase mold preheating temperature by 30-50°C (PER ESEMPIO., from 150°C to 180°C). |
| Undercasting (Riempimento incompleto) | 1. Metal temperature too low (low fluidity)2. No overflow groove (no room for shrinkage)3. Narrow gate (restricts flow) | 1. Raise melting temperature by 20-30°C (PER ESEMPIO., ADC12 from 720°C to 750°C).2. Add a 5mm-wide overflow groove to the mold’s highest point.3. Widen the gate from 3mm to 5mm (use a file for small adjustments). |
| Mold Sticking | 1. Insufficient release agent2. Mold not cleaned (residual oxide scales)3. Demolded too early (metal still soft) | 1. Apply a second thin layer of release agent (grafite + olio) and let dry.2. Scrub the cavity with a wire brush and acetone to remove residues.3. Prolungare il tempo di raffreddamento di 2-3 minuti (wait until mold surface is <80° C.). |
| Dimensional Deviation (Too Big/Small) | 1. Mold thermal expansion (steel expands when hot)2. No shrinkage allowance (metal shrinks when cooling)3. Uneven pressure (distorts the part) | 1. Switch to cast iron mold (lower thermal expansion: 10.8×10⁻⁶/°C vs. steel’s 13×10⁻⁶/°C).2. Aggiungere 1.5-2% shrinkage allowance to the mold design (PER ESEMPIO., 100mm part → 102mm cavity).3. Use a torque wrench to apply even pressure (PER ESEMPIO., 20 N·m for screw jacks). |
4. Applicazioni pratiche: Where Simple Die Casting Shines
Simple die casting isn’t for mass production—but it’s invaluable for four key scenarios. This section uses Esempi di casi to illustrate its real-world value:
4.1 Sviluppo del prototipo (Fast Design Validation)
Small product teams often need functional prototypes to test fit, Tatto, and assembly—simple die casting delivers this in hours, Non settimane.
Esempio: A startup developing a small electric tool needed a prototype aluminum motor housing. Using simple die casting:
- Muffa: 20mm steel plate, wire-cut cavity (costo: $300).
- Materiale: Recycled ADC12 aluminum (costo: $20).
- Risultato: First prototype ready in 3 ore; tested assembly with other parts, identified a 2mm misalignment in the mounting hole—fixed the mold and made a revised prototype the same day.
Risparmio dei costi: contro. 3D Printing (SLS aluminum: \(500/prototipo) or industrial die casting (die cost: \)10,000)—saved 90%+ sui costi del prototipo.
4.2 Educational Demonstrations (Hands-On Learning)
Schools and training centers use simple die casting to teach metal solidification principles—students see casting in action, not just read about it.
Impostare: Use Wood’s metal (melts in hot water, 70° C.) and a plastic mold (sicuro per i principianti). Students pour the molten metal, apply light pressure, and watch it solidify—learning about shrinkage, exhaust, and release agents firsthand.
Beneficio: 80% of students report better understanding of casting vs. textbook learning (per a 2023 engineering education study).
4.3 Emergency Maintenance (On-Site Repairs)
In remote areas or during equipment breakdowns, simple die casting can repair worn parts quickly—avoiding costly downtime.
Esempio: A farm’s tractor gearbox had a worn brass bearing housing. Using simple die casting:
- Muffa: Sand mold (made on-site with sand + acqua + clay, costo: $5).
- Materiale: Melted old brass fittings (costo: $15).
- Risultato: Repaired housing installed in 4 hours—tractor back in use the same day. Industrial repair would have taken 3 days and cost $1,000+.
4.4 Artistic Casting (Custom Metal Art)
Artists use simple die casting (combined with lost-wax techniques) to create unique metal sculptures—retaining handmade details industrial processes can’t replicate.
Processo: 1. Carve a wax sculpture. 2. Make a sand mold around it. 3. Melt bronze or copper (using a small furnace). 4. Pour into the mold, apply light pressure. 5. Break the mold to reveal the sculpture.
Esempio: A metal artist created 5 limited-edition copper bowls using this method—each sold for \(500, with total material cost <\)100.
5. Costo & Efficiency Analysis (Is It Worth It?)
Simple die casting’s biggest appeal is its low cost—but it’s important to understand its efficiency limits. Di seguito è riportato un real-world cost breakdown for a 100-part run of small aluminum brackets (50g ciascuno):
| Categoria dei costi | Dettagli | Costo totale (100 Parti) | Costo per parte |
| Materiali | Recycled ADC12 aluminum: \(2/kg × 5kg (100 parts × 50g) = \)10 | $10 | $0.10 |
| Muffa | Steel plate (20mm × 100mm × 100mm): \(50; wire cutting: \)150 | $200 | $2.00 |
| Utensili | Small electric furnace (rented: $20/giorno), screw jack (already owned) | $20 | $0.20 |
| Lavoro | 8 ore in totale (prep, fusione, versare, finitura): $25/ora | $200 | $2.00 |
| Totale | – | $430 | $4.30 |
Key Efficiency Takeaways:
- Velocità: 100 parts take 1-2 giorni (contro. industrial die casting’s 1-2 hours—but industrial setup takes months).
- Scalabilità: Not for runs >500 parts—mold wear and manual labor make it inefficient.
- Costo vs. Alternative: Cheaper than 3D printing (\(10-20/parte) or industrial die casting (die cost alone \)50,000+), but more expensive than mass-produced parts ($0.50-1/parte).
6. Yigu Technology’s Perspective on Simple Die Casting
Alla tecnologia Yigu, we see simple die casting as a “gateway technology”—it makes casting accessible to small teams, studenti, and enthusiasts who can’t afford industrial equipment. Troppo spesso, le persone lo respingono come “dilettante,” ma il suo valore sta in velocità e flessibilità, non precisione.
Consigliamo la pressofusione semplice per: 1. Prototipi in fase iniziale (convalidare i progetti prima di investire in stampi industriali). 2. Parti personalizzate a basso volume (1-100 unità). 3. Scenari educativi o di emergenza. Per i clienti che passano alla produzione di massa, we help them use simple die casting prototypes to refine designs—cutting industrial die revision costs by 40%.
We also advise focusing on material selection: Start with zinc alloys (easy to melt, low defect rate) before moving to aluminum. And always prioritize safety—even simple casting involves hot metal, so proper