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FrenchA full view of our 1,250-ton die casting production line. A technician is picking up a finished casting as the robot above prepares the die casting mold for another injection.
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Al Falah Factoryfor Engineering and Metal Industries.
die casting
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Testing.
Before we begin the aluminum die casting process, we use a spectrometer to test the chemical composition of the aluminum ingot to ensure the specifications fall between 0-5% difference in purity.
Melting.
The aluminum ingots go through a melting process at one of eight die casting machine stations, each equipped with a melting furnace. The only step that requires human interaction is placing the ingot into the furnace. The rest is automated.
Casting.
Once melted, the molten aluminum is injected into the die. We offer a wide range of products that vary in size and weight as well as the machines required to produce them, including a 2,500 tons machine that can cast most powertrain components.
Quality Assurance.
With advancements in technology, quality assurance is no longer dependent on cutting the product to test for porosity. We use an X-ray machine that allows us to accept and reject components more accurately.
Finishing & Shipping.
After the quality assurance process, components are trimmed, deburred, polished and burnished. We also offer surface finishing options such as painting and coating, depending on the component and your needs. Once completed within specs, the components are packaged and shipped.
Why Choose VPIC for Aluminum Die Casting?
VPIC’s aluminum die casting services encompass a full range of primary and secondary operations to produce components of all sizes at an unmatched level of quality.
Flexibility
When producing aluminum die casting parts, we remain flexible to accommodate the wide range of component sizes our clients require. Using the right machine to handle between 350-2,500 tons, we produce everything from small components all the way to engine blocks.
Full Range of Services
We provide a full range of services outside of the primary operation of die casting parts. Our secondary in-house operations include painting, CNC machining, stamping, injection molding, welding and more.
Quality
One of our key differentiators is our dedication to the robotic automation process. When it comes to aluminum die casting, the only process that requires human interaction is loading the ingot into the furnace. The rest is automated. Our quality assurance process is conducted by X-ray machines, which reduces the risk of human error.