Die casting parts surface finishes are versatility finshing treatments. Today there is a complete die casting parts surface finish service. Include of polishing,electroplating, powder coating, anozide and shot blastering finishes etc. Different surface finish, request different suface preparation. For example, the requirement of powder coating is not so strict, only the surface of casting part is clean and not any dirt or other burr and regardless of smoothness and uneven areas.
But the requirement of electroplating is very rigid, the surface of metal part should be smooth, even area and clean surface an no dirt and grease. Otherwise, rough and dirt surface can impact the quality of electroplating strictly, lead to its shorter durability and applications. Different surface finishes require different surface grain grade demands, this mean distinct cost investment and detailed design requirements.
Contents Of Table
- What is Die Casting Parts Surface Finish ?
- Why Choose TangSheng Die Casting Parts Surface Finish Services ?
What is Die Casting Parts Surface Finish?
Die casting parts surface finish is typically the appearance, texture, and smoothness of the surface of the cast part. Diversity surface finishes for die castings, which can be realized through secondary processes. It includes both the natural surface condition of as-cast parts and additional finishing processes. The surface finish of die casting parts directly affects their appearance, corrosion resistance, wear resistance, dimensional accuracy, electrical performance, and suitability for different applications. We can treat metal die casting pars from 3 angle views in the below information.
As-Cast Parts
These parts mean the precision die casting parts ejected from the steel cast die, remain natural rough surface. Miniature zinc die casting part experiences fast cooling and solidifying at low melting temperature, and a bit shrinkage, create very smooth surface finish. While larger aluminum die casting part require a longer cooling and solidifying to form precision cast part. Because there is much hytrogen within molten aluminum alloy, porosity surface and pinhole surface is inevitable. So more secondery operations are needed.
Mechanical Finishing
- Mechanical Deburring: Put the as-cast parts into the gigs, Removing the burs, excess gating material by ultra-sonic viberation machines.
- CNC Machining :Achieve close-tight tolerance dimensional stability, these near net-shaped parts require CNC machining approach. Using effective cutting tools to remove excess material on the surface of cast parts, such as parting line, sharp edges.
- Polishing Process: From the metal part rough polishing, medium polishing to mirror polishing, depends on the requirement of respecific surface roughness grain grade, various surface roughness level polishing process is ready for all die casting parts.
- Abrasive Grinding: Batch mass production needs proper gigs to enhance production rates and time-saving. Sand-belt grinding is high effective, and create stain surface treatment for these die cast parts.
Surface Treatments
In order to prolong the lifespan of the die cast part and suitable of application environments of the cast part, various surface treatments are adpoted. Like anodizing, chrome-plating, satin-nickel plating, electrophoresis and powder-coating and painting. These treatments require different surface roughness levels.
Summarize the comparison among them in detail
| Surface Treatment Type | Required Surface Roughness (Ra) | Surface Requirement |
|---|---|---|
| Chrome-plating | Ra = 0.05\sim0.20\ \mu m | High mirror smoothness |
| Bright Nickel Plating | Ra = 0.10\sim0.40\ \mu m | Uniform reflective surface |
| Satin Nickel Plating | Ra = 0.40\sim0.80\ \mu m | Fine directional texture |
| Copper Plating | Ra = 0.20\sim0.8\ \mu m | Moderate smoothness |
| Powder Coating / Painting | Ra = 1.6\sim3.2\ \mu m | Mechanical ahesion surface |
For zinc die casting and aluminum die casting components, selecting the proper surface finish is an important step to achieve both functional performance and aesthetic requirements. We will choose right surface finish method to treat die castings in accodance with requirements of die castings’ functionality and applications in specific industries.
Why Is Surface Finish Important for Die Casting Parts?
The surface of all die casting parts are rough although high precision cast die and technique of die casting during die casting process. So these metal die castings allow secondary operations to improve and smoothen the surface of metal parts. Well-experienced die casting supplier all employs mechanical durring machines and polishing equipment to achieve different surface roughness level to be ready for further finshing treatments. The secondery operations include the follow approaches.
- Sand blastering
- Sand-belt grinding
- Viberation deburring
- Serial Polishing
- CNC machining
- Manual Chewling
Zin die casting part or aluminum die casting part, on surface of which there is often a thin layer of oxidation over time, may affect the lifespan and functionalities directly. In order to ensure extending the life time of the cast parts and normal usage of the cast part, finishing treatments are available for them.
- Chrome-plating
- Nickel-plating
- Electrophoresis
- Copper-plating
- Powder-coating and painting
The above operations help improving the performance of the cast parts, the advantage show the main points.
Improved Apperance
Chrome-plating and nickel-plating create bright glossy, and decorate the die cast part better, make them more attractive and aesthetics. Especially automotive zinc die casting components and miniature high precision consumer electronical devices require luxurious feeling and noble sylish.
Enhanced Corrosion Resistance
Nickel-plating creates strong corrosion resistance protecting layer cover for zinc and aluminum die casting parts. They can work on some high aid and salt environments. It is suitable for automotive door handles, antennas and mirror housings and communication equipment components withstand worse weather and rigid geographical locations.
Better Wear Resistance
Chrome-plating and copper-plating makes the surface of substance more harder. Better wear resistance make the die casting part longer lifespan. Zinc and aluminum cast parts need chrome-plating, they allow medium copper-coating to enhance adhesion feature for chrome-plating. Even more increasing the hardness of the surface of cast parts.
Additional Functionalities
They requie be plated by copper, silver, gold When the die casting parts want to some special functionalities. Copper, gold and silver have excellent electrical conductivity, make the zinc and aluminum die casting parts more electrical conductivity.
In summary, secondery operations for die casting parts makes the achievement of improved apperance, the enhancement of corrosion resistance,better wear resistance and additional functionalities.
Die Casting Parts Surface Finish Types
As The follow list main options for die casting surface finishing:
1. As-Cast Finish
This is the natural finish of metal die casting part directly from the die casting mold. It is original die casting part,which may have a matte or slightly glossy look. These die castings may carry some small burrs ,such as flashing , part lines and sharp edges , it is necessary to do post-process after casting them, and improve its surface finish better.
2. Machined Finish
Die castings is machined by machining process to remove excess burrs and achive a high level smooth and uniform surface finish . The rough surface of die castings becomes smooth and glossy, and ensure fitting the requirement of component installment. Its tolerance is deciced on which functionality and actual usage.
Polishing
Polishing process remove residues and grease on the cast parts so that these parts can be treated. The die casting part polishing process is indispensable,which make the cast parts reflective surface, with a smooth texture. These polish finishes effection will be decided by the demand of next surface finish can be proceeded smoothly. Precision electric components, Decorative parts, consumer products like exquisite gift, automotive trim, and other components requiring a sleek appearance.
4. Shot Blasted Or Bead Blasted Finish
Shot blasting or bead blasting means bombarding the surface with small particles to generate a uniform, textured surface. It is one types of effective treatments that improving the surface of metal die castings. More rugged or matte finish is required, such as industrial equipment, non-decorative housings, and outdoor applications.
5. Plated
Die-cast parts electroplating includes of chrome, nickel and zincto plated. Die Casting Parts Electroplating belongs to super surface finish level process method for metal die casting part, coating nickel, copper, gold and chrome on the surface of metal casting parts. These die casting surface finish material is expensive, but the effection is best. It can create a metallic look (e.g., chrome-plated). Consumer goods, automotive parts, and appliances components are all electroplated in real life.
6. Painted Or Power-Coated Finish
Painting or powder coating finish means coating a protective or decorative layer of paint or polymer powder on the surface of the die-cast part. Prolong the life of the die castings and decorative appearance. Powder coating offers a thin, durable protective finish. They are suitable for consumer products, outdoor equipment, and parts exposed to harsh environments.
7. Anodized Finish (For Aluminum De Castings)
Anodizing is an electrochemical process, which create the oxide layer on aluminum die-cast parts. Enhance corrosion resistance and allowing for coloring. Matte to semi-glossy, from natural silver to black, gold, or other custom colors. The matte may need shot blastered to treat contrast matte surface effection. These anodized aluminum die castings are used in Electronics, consumer products, automotive trim, and architectural components.
8. Textured Or Patterned Finish
Text finish is very common surface finish, engraving the texture an pattern on the core of the cast die, directly marks the texture an pattern on the surface of the cast parts.Their surface finish can mark on the surface of die castings permanently.
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Surface Finish Cost Comparison Between Zinc Alloy and Aluminum Alloy Die Casting Parts
The surface finishing cost of die casting parts depends on alloy characteristics, surface quality requirements, part geometry, and the selected finishing process. Although both zinc alloy and aluminum alloy die castings can achieve excellent surface finishes, their preparation requirements and finishing costs are different.
| Surface Finish Process | Zinc Alloy Die Casting | Aluminum Alloy Die Casting |
|---|---|---|
| As-Cast Finish | Lower cost due to smoother casting surface | Require more secondary operations |
| Polishing | Easier polishing , save labor cost | Remove oxide layare, addtional process cost |
| Electroplating | Excellent metal adhesion, remove dirt, grease and even smooth surface | Polishing + Additional porosity-sealing operations. |
| Powder-Coating | shot blasering required and cleaning | shot-blistering and conversion coating |
| Anodziing | Not applicable | Chemical reaction, most common finishing treatment |
| Shot blastering | Common | Common |
Why Choose TangSheng Die Casting Parts Surface Finish Services ?
Professional Services and High Quality
High Quality Parts
Precision casting die and automated streamline high quality parts. And insist on conducting strict quality contol on each process phrase. We permamently maintain 100% inspection.
Engineering Team Support
Well-experienced Engineering team supports die casting part and casting die design and precision process for high speed steel die manufacturing. Ensuring mass production in high efficiency in high volume. With consistent high quality product output.
Meet Various Requirements
Meet various requirement of die casting parts surface finish in many industries, such as automotive, commnunicatioin, electronic consumer, medical and heavy industrial equipment. The comany passes international industrial authorized certified system,like ISO 9001 and IATF 16949.