Step 01
Die spray and close
The die faces are sprayed with release agent for lubrication and thermal control; the moving half closes and locks.
High Pressure Die Casting · Thirumudivakkam, Chennai
HPDC Aluminium
Die Casting Manufacturer
Our cold-chamber HPDC cells inject aluminium at high velocity and pressure into hardened steel dies, producing thin-walled, dimensionally consistent castings at production cycle times.
- Machine type
- Cold-chamber HPDC
- Clamping force
- 250T · 350T
- Max shot weight
- 3.0 kg Al
- Melt hold
- 685°C ± 5°C
How high pressure die casting works
In cold-chamber HPDC the molten aluminium is ladled into a horizontal shot sleeve outside the furnace — aluminium would attack a submerged (hot-chamber) injection system. A hydraulic plunger then drives the metal into the die in three phases: a slow first phase that fills the sleeve without trapping air, a fast second phase that fills the cavity in tens of milliseconds, and an intensification phase that applies high pressure while the metal solidifies to feed shrinkage.
The clamping force of the machine must exceed the force of the metal pressure acting on the projected area of the part and runners. That is why part size and machine tonnage are matched during feasibility — a larger projected area needs a larger machine.
Process
An HPDC cycle at Sunmax
A typical cycle on our cells, from die close to part extraction.
Step 02
Ladling
A metered dose of degassed alloy is transferred into the shot sleeve.
Step 03
Slow and fast shot
The plunger advances slowly to push air ahead, then accelerates to fill the cavity.
Step 04
Intensification
Pressure is multiplied at the end of fill to compact the metal and reduce shrinkage porosity.
Step 05
Solidification
Die cooling channels extract heat; dwell time is set per part thickness.
Step 06
Open and extract
The die opens and the casting is ejected and removed for trimming.
Capabilities
Our HPDC cells
Specifications as installed. Full machine table on the machinery page.
| 350T Toshiba | Platen 935 × 935 mm · tie-bar distance 650 × 650 mm |
|---|---|
| 250T Zitai | Die height 250 – 650 mm · tie-bar distance 580 × 580 mm · 2500 kN |
HPDC alloys
HPDC alloys are silicon-rich for fluidity and die release.
- ADC12
- Si 9.6–12.0 % — excellent fluidity for thin walls
- A380
- Si 7.5–9.5 %, Cu 3.0–4.0 % — balanced strength
- AlSi10Mg
- Si 9.0–11.0 %, Mg 0.2–0.5 % — higher elongation
Parts suited to HPDC
HPDC is the right choice when a part has:
- Thin walls (typically 2–4 mm) over large areas
- Many integrated features — ribs, bosses, mounting points
- Repeat demand in the thousands to hundreds of thousands per year
- A need for good as-cast surface finish
Industries
Industries we supply with hpdc
- Gas porosity — melt degassing and controlled slow-shot speed
- Shrinkage porosity — intensification pressure and thermal balance of the die
- Cold shuts and misruns — melt and die temperature control
- Soldering and die wear — die spray and preventive die maintenance
FAQ
HPDC — frequently asked questions
What is the difference between HPDC and pressure die casting?
In India the terms are used interchangeably. Both describe injecting molten metal into a steel die under high pressure. For aluminium the cold-chamber variant is used.
Why is aluminium cast in cold-chamber machines?
Molten aluminium attacks iron components, so it cannot sit in a submerged injection system. It is ladled into a shot sleeve for each shot instead.
How do I know which machine tonnage my part needs?
Tonnage depends on the projected area of the part plus runners and the metal pressure used. We calculate it during feasibility from your 3D model.
Can HPDC castings be pressure-tight?
Yes, with the right design, gating and process control. Where leak tightness is critical we agree a test method and acceptance level at the RFQ stage.
Related capabilities
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Share your 3D model or drawing, alloy and annual quantity. Our engineering team reviews every enquiry for manufacturability before quoting.