Cold Chamber Casting Services

Frigate’s cold chamber casting delivers excellent corrosion resistance and durability for your finished products. We focus on using the best methods and materials to achieve the best results for your projects.

Our Clients

Advantages of Cold Chamber Casting Services

Rapid Production Rates

Cold chamber die casting has longer cycle times because metal is ladled manually. However, it still supports fast production and is ideal for large-scale manufacturing.

Strong and Durable Casting

You get parts with exceptional strength and durability. High pressure is used to force the metal into intricate molds, producing dense and microstructured castings.

Excellent Dimensional Accuracy

Get exceptional dimensional accuracy and stability with precise molds and a specialized production process. Parts maintain tight tolerances, making this method ideal for creating intricate shapes with high precision.

Thinner Walls

We use high pressure to produce complex parts with thin walls. This method ensures that the parts maintain strong, reliable properties even with intricate designs.

Frigate Cold Chamber Die Casting For Strong and Durable Parts

Frigate’s cold chamber die casting process is perfect for creating thicker metal castings. The process separates the melting pot from the injector, reducing corrosion.

You benefit from cost-efficient and effective methods that produce various shapes and elements. Parts made through this process are highly durable and long-lasting.

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Our Cold Chamber Die Casting Process

Metal Melting

The process begins by melting the metal in a separate furnace outside the casting machine. This setup differs from hot chamber casting, where the metal is melted within the machine.

Metal Transfer

Once molten, the metal is ladled into the cold chamber, a cylinder within the casting machine.

Injection

A plunger or piston forces the molten metal into the die (mold) at high pressure. This pressure ensures that the metal fills every cavity and detail of the die.

Cooling

The metal solidifies quickly as it cools within the die, forming the desired shape. The cooling time can depend on the metal and the thickness of the part.

Ejection

After metal solidification, the die opens, and the cast part is ejected. Any excess metal, like flash or sprues, is removed.

Finishing

To achieve the final product, the cast part may undergo additional finishing processes. These can include trimming, machining, or surface treatments.

Cold Chamber Die Casting Materials

There are multiple materials that can be used for cold chamber die casting services. The choice of casting materials depends upon specific properties and suitability.

Aluminum Alloys

Aluminum alloys are commonly used. They offer a good balance of strength, are lightweight, and are corrosion-resistant, making them ideal for automotive and aerospace applications.

Magnesium Alloys

Magnesium alloys are known for being lightweight and strong. They are used in industries where reducing weight is important. sElectronics and automotive parts are examples of such industries.

Copper Alloys

Copper alloys provide excellent electrical conductivity and corrosion resistance. This makes them perfect for electrical components.

Brass Alloys

Brass alloys are durable and attractive. They are often used for decorative parts and applications where aesthetics matter.

Precision and Speed with Frigate's Cold Chamber Casting

Cold chamber die casting is perfect for aluminum and magnesium alloys. It produces durable parts with high precision. We excel in creating components with tight tolerances and thin walls. Our process uses high pressure and speed to fill the die completely. This results in parts with minimal porosity.

Compliance for Cold Chamber Casting Services

We adhere strictly to industry standards for Cold Chamber Casting, ensuring top-tier precision, safety, and environmental responsibility. Our processes are rigorously tested and monitored to meet regulatory compliance, from quality control to sustainable practices. We guarantee the highest performance and product reliability by aligning with international standards. Below are the specific certifications and compliance measures that support our technical excellence:

ISO 9001:2015

This certification confirms that Frigate Die Casting Services adheres to global standards for quality management systems. It ensures consistent product quality, continuous improvement, and customer satisfaction across all our Cold Chamber Casting processes.

ASTM B85

A key standard for aluminum alloy die castings, ASTM B85 outlines the specifications for the material properties of aluminum alloys used in our Cold Chamber Casting. It ensures that the alloys meet the required mechanical, chemical, and dimensional properties, which are crucial for producing high-strength, reliable cast components.

REACH Compliance (EC No. 1907/2006)

Frigate complies with the European Union’s REACH (Registration, Evaluation, Authorization, and Restriction of Chemicals) regulation. This ensures that the materials used in our Cold Chamber Casting are safe for human health and the environment, reducing the risk of harmful substances in our products.

RoHS Directive (2011/65/EU)

This directive restricts using certain hazardous substances in electrical and electronic equipment. By following RoHS standards, Frigate ensures that all castings used in electronic components are free from lead, mercury, cadmium, and other restricted materials, making our products safer and more sustainable.

ISO 14001:2015

This certification establishes a framework for effective environmental management systems. It demonstrates Frigate’s commitment to reducing the environmental impact of our Cold Chamber Casting processes by managing resources efficiently, reducing waste, and minimizing emissions.

OSHA Standards (29 CFR 1910)

The Occupational Safety and Health Administration (OSHA) standards are followed to maintain a safe working environment. These regulations focus on preventing workplace hazards and ensuring Frigate’s casting operations protect workers and the surrounding environment.

SAE J438

This standard is specific to the automotive and aerospace industries, focusing on die-casting specifications. By adhering to SAE J438, Frigate ensures that all cast components meet the performance standards required for high-stress, high-performance applications in these sectors.

Tolerance for Cold Chamber Casting Services

Cavity Pressure

40 MPa to 120 MPa

The pressure exerted on the material inside the mold cavity. Affects material flow and final part density.

Injection Speed

2 m/s to 6 m/s

Speed at which molten metal is injected into the mold cavity. Impacts fill efficiency and defect occurrence (e.g., air entrapment).

Injection Time

1 second to 4 seconds

Duration for which molten metal is injected into the mold. Affects the final shape, surface quality, and material distribution.

Cooling Rate

2°C/s to 10°C/s

The speed at which the molten metal cools and solidifies. Affects the hardness, strength, and grain structure of the casting.

Mold Temperature

150°C to 300°C

The temperature of the mold during casting. Ensures that the metal solidifies at the correct rate, minimizing defects.

Tensile Strength

200 MPa to 500 MPa

The maximum stress a material can withstand while being stretched or pulled before breaking. Essential for structural integrity in critical applications.

Yield Strength

150 MPa to 400 MPa

The stress at which a material begins to deform plastically. Important for maintaining the shape and durability of the casting under load.

Elongation

1% to 10%

The extent to which the casting material can stretch before breaking. A critical parameter for ensuring ductility and preventing brittle fractures.

Hardness (Brinell)

40 HB to 100 HB

Measures the hardness of the casting material. A higher value indicates greater resistance to indentation and wear.

Fatigue Strength

150 MPa to 400 MPa

The ability of the material to withstand repeated loading and unloading. Important for components subjected to cyclic stresses.

Thermal Conductivity

100 W/m·K to 200 W/m·K

Measures the material's ability to conduct heat. Important for components exposed to high temperatures or thermal cycling.

Dimensional Stability

±0.2 mm to ±0.5 mm

The ability of the casting to retain its dimensions under temperature changes and mechanical stress. Crucial for tight-fitting parts.

Cyclic Thermal Expansion

10 × 10^-6/°C to 20 × 10^-6/°C

Rate at which the casting expands or contracts with temperature changes. Critical for components exposed to varying thermal conditions.

Grain Structure

Fine, Medium, or Coarse

The microstructure of the casting, which influences the mechanical properties, such as strength and toughness. Fine grains are typically preferred for high-strength applications.

Quality Testing Standards for Cold Chamber Casting Services

Cavity Pressure

Pressure Transducer Monitoring

Measures the pressure exerted on the molten metal during injection to ensure optimal material flow and fill efficiency.

Injection Speed

High-Speed Data Logging

Monitors the speed at which molten metal is injected into the mold, ensuring it meets precise flow requirements.

Injection Time

Time Measurement Systems

Records the exact duration of molten metal injection to ensure the casting process is optimized for each part.

Cooling Rate

Thermal Analysis (Thermocouples)

Measures the cooling rate of the metal within the mold to control the solidification process and minimize defects like shrinkage.

Thermal Conductivity

Laser Flash Analysis

Tests the rate at which heat travels through the material, impacting the cooling and solidification process.

Elongation at Break

Universal Testing Machine (UTM)

Determines the material's ductility by measuring its elongation before failure, which is vital for impact resistance and fatigue life.

Tensile Modulus

Tensile Testing

Measures the material’s stiffness or resistance to deformation under tensile stress, important for load-bearing applications.

Fatigue Crack Growth

Fatigue Testing (ASTM E466)

Determines the rate of crack propagation under cyclic loading, essential for evaluating the longevity of parts under repeated stress.

Cyclic Hardness

Cyclic Hardness Testing (ASTM E384)

Measures changes in hardness over multiple loading cycles, indicating the material's response to fatigue or wear.

Microstructure Homogeneity

Scanning Electron Microscopy (SEM)

Analyzes the consistency of the microstructure, ensuring uniform grain distribution and phase formation for superior material properties.

Impact Toughness

Izod Impact Testing (ASTM D256)

Evaluates the material's resistance to sudden force or shock, crucial for components exposed to high impact stresses.

Residual Solvent Testing

Gas Chromatography (GC)

Identifies any remaining solvents or volatile materials in the casting, ensuring that the product is free of harmful residues.

Hardness Profile

Vickers Hardness Test (ASTM E92)

Provides detailed hardness measurements across the surface and interior of the casting to evaluate uniformity and quality.

Dimensional Stability

Coordinate Measuring Machine (CMM)

Assesses long-term dimensional stability under varying temperature and mechanical stress conditions, ensuring the casting retains its shape.

Weldability

Welding Simulation and Testing

Tests the ability of the casting material to be welded without experiencing failure, such as cracking or porosity.

Surface Integrity

Eddy Current Testing

Detects subsurface defects, such as cracks or voids, in the casting material that could impact its structural integrity.

Magnetic Permeability

Magnetic Testing

Measures the casting’s ability to conduct magnetic fields, important for parts used in electromagnetic applications.

Gas Porosity

Gas Permeability Testing

Determines the porosity caused by trapped gases, ensuring castings have minimal internal voids or defects.

Dimensional Deviation

X-ray Inspection or Computed Tomography (CT)

Provides high-resolution imaging of the internal and external dimensions of the casting to identify any inconsistencies or defects.

Frigate Cold Chamber Casting for the Aerospace Industry

Frigate provides specialized cold chamber casting services tailored to the aerospace industry. Our process delivers high-precision components that adhere to stringent aerospace standards, using advanced technology to achieve tight tolerances and superior quality.

Cold chamber casting is ideal for producing durable, high-strength parts from aluminum, magnesium, and other non-ferrous alloys. These materials offer the required strength-to-weight ratio essential for aerospace applications. Our process ensures excellent surface finishes and precise dimensions, making it perfect for aircraft engine components, housings, and structural elements.

Industries We Serve

What You Get

Frigate offers customized casting solutions to optimize your project and save on costs. Our responsive team ensures timely support and efficient service.

Advanced Testing

We use top-notch testing instruments like chemical analyzers and spectrometers for precise quality control.

Versatile Metal Alloys

From prototyping to mass production, you can cast components using all types of metal alloys.

Expert Team

Our skilled engineers provide innovative solutions and high-quality production.

Diverse Casting Methods

Along with cold chamber die casting you can also contact us for sand casting, lost foam casting, shell mold casting, and lost wax investment casting.

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What Our Customers Say about Frigate

I would strongly recommend Frigate to anyone who wants to do Rapid Prototyping, and 3D Printing and take their ideas to manufacturing. One firm doing all kinds of Product Development!

Thank you so much for your great support so far. Overall, the sheet metal work of the Plotbot Pro was done in an awesome way.Special Mention: The powder coat looks cooler!

The next disruption is happening in Prototyping & Manufacturing on-demand and Frigate is leading the way!I personally believe the Frigate's way of IIOT enabled cloud platform with Al.

I am absolutely happy to work with supplier like Frigate who were quite proactive & result oriented . Frigate has high willingness team who has strong know how & their passion towards the products & process were absolutely thrilling.

Working with Frigate has been great. Their proactive, results-driven approach and expertise shine through in every project. It's been a pleasure collaborating with them.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

What is the role of the cold chamber in the casting process?

The cold chamber is a part of the die-casting machine where molten metal is injected into the mold. Unlike hot chamber casting, where the injection unit is molten, the cold chamber system melts the metal in a separate furnace. This setup helps when using metals with high melting points, like aluminum.

How does the injection process work in cold chamber casting?

In cold chamber casting, the molten metal is first ladled from the furnace into the injection chamber. Then, a plunger pushes the metal into the mold at high pressure. This quick injection helps create precise shapes and improves surface quality, which is crucial for complex designs.

Why is cooling time important in cold chamber casting?

Cooling time is the period the metal needs to solidify in the mold. The cooling time can affect the final part's quality and dimensions in cold chamber casting. A cooling time that is too short may lead to defects like warping, while a cooling time that is too long can reduce production efficiency. Finding the right balance is key.

What types of alloys are best suited for cold chamber casting?

Cold chamber casting is ideal for high-temperature aluminum, magnesium, and copper alloys. These metals need the cold chamber process because their melting points are too high for hot chamber casting, ensuring quality parts without damaging the machine.

How does the cycle time in cold chamber casting compare to hot chamber casting?

The cycle time in cold chamber casting is usually longer than in hot chamber casting. This is because the metal must be ladled into the chamber before injection. However, the precise nature of cold chamber casting can lead to fewer defects, making the overall process more efficient for certain applications.

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ