Die Casting Mold Core

Name: Mold Core Insert for Casting Under Pressure – Frigate
Price: 249.00 USD
Availability: InStock

Die Casting Mold Core is engineered with high hot yield strength and thermal conductivity control to resist micro-crack propagation under cyclic thermal loads. Tool steels are vacuum heat-treated and tempered at precise intervals to align with thermal expansion profiles of the die cavity. Surface nitriding further enhances fatigue threshold without compromising dimensional control.

Material Specification

H13 (DIN 1.2344), H11, SKD61, QRO-90 Supreme, Maraging Steel (for high-temp alloys)

Hardness (HRC)

46-50 HRC (H13), 44-48 HRC (H11), 48-52 HRC (QRO-90)

Surface Finish (Ra/RMS)

Core/Cavity – 0.4–0.8 µm, Ejector Pins – 0.8–1.6 µm, Non-Critical – 1.6–3.2 µm

Dimensional Tolerances

Critical Features – ±0.02 mm, Overall Dimensions – ±0.05 mm, Draft Angles – +0.25°/-0°

Core & Cavity Geometry

As per 3D CAD Model (STEP/IGES) with ±0.01 mm profile tolerance

Product Description

Die Casting Mold Core maintains surface integrity in high-velocity metal impact zones through application of hard coatings such as PVD CrN and plasma nitrides. Erosion-prone regions are reinforced using localized tool steel overlays and post-machining thermal stress relief, extending service life during sustained exposure to turbulent melt flow.

Cooling Channel Design

Diameter – 8-12 mm, Pitch – 30-50 mm, Position Tolerance – ±0.2 mm, Flow Rate – 10-15 L/min

Ejection System Features

Ejector Pins – Ø3–12 mm (SKD61, 50+ HRC), Sleeves – H7/g6 fit, Lifter Clearance – 0.05–0.1 mm

Vent & Overflow Features

Vent Depth – 0.1–0.3 mm, Width – 5-15 mm, Overflow Volume – 5–15% of shot volume

Coating/Surface Treatment

Nitriding (0.1–0.3 mm), AlCrN/TiAlN Coating, or EDM Glazing (for aluminum alloys)

Certification Standard

NADCA #207-2003, ISO 9001, IATF 16949 (Automotive), AMS 2759 (Heat Treatment)

Technical Advantages

Die Casting Mold Core is manufactured to hold tolerance bands within ±5 microns across the functional axis, using precision EDM and five-axis simultaneous milling. Material phase stability is ensured via sub-zero treatment, minimizing distortion during thermal cycling and preserving cavity geometry throughout production.

Die Casting Mold Core ensures reliable part release by integrating optimized draft geometry with sub-0.4 Ra surface finish. Application of dry-film lubricants or PVD surface coatings enables clean separation at ejection, reducing buildup of aluminum soldering and improving cavity uptime.

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Industry Applications

Automotive Transmission Housings

Die Casting Mold Core enables precise internal geometry control for complex housing cavities under high-pressure aluminum alloy casting conditions.

Electric Vehicle Motor Enclosures

Die Casting Mold Core supports tight thermal tolerance and dimensional uniformity for casted motor housings exposed to fluctuating electromagnetic and thermal loads.

Consumer Electronics Casings

Die Casting Mold Core ensures fine-fin geometry accuracy for aluminum-based heat sinks requiring high surface-area-to-mass ratio with thermal consistency.

Aerospace Structural Brackets

Die Casting Mold Core achieves structural symmetry and wall thickness repeatability in lightweight aerospace-grade magnesium alloy bracket production.

Industrial Pump Impellers

Die Casting Mold Core maintains critical vane spacing and flow channel uniformity in high-velocity fluid impeller castings with complex curvature.

Telecom Connector Housings

Die Casting Mold Core provides micron-level cavity detailing for multi-port connector castings requiring electromagnetic shielding and thermal dissipation features.

Conformal Cooling Integration

Die Casting Mold Core incorporates conformal cooling circuits using DMLS or multi-part brazed assemblies to manage localized hot spots. This enables faster solidification, reduces thermal gradients, and maintains thermal equilibrium in deep-cavity core regions, directly improving casting density and dimensional accuracy.

Die Casting Mold Core is produced with self-locating shoulders, keyed seats, and anti-rotation slots to facilitate repeatable installation. Tolerances at mating interfaces are ground to within 10 microns, ensuring proper alignment without secondary fitting or shimming during core changeover.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure uniform heat distribution in Die Casting Mold Core during high-pressure casting?

Frigate uses thermally optimized tool steels and integrates conformal cooling paths via additive manufacturing or deep-hole drilling. Heat simulations are conducted to predict gradient zones and core expansion behavior. Each Die Casting Mold Core design includes cooling channel validation using thermal flow analysis. This ensures minimal thermal shock and dimensional drift during repeated cycles.

What techniques does Frigate use to control core dimensional distortion during post-processing?

Frigate applies sub-zero cryogenic treatment after hardening to stabilize the Die Casting Mold Core microstructure. This reduces retained austenite and controls volumetric distortion. Cores are CNC-finished post-treatment to restore tolerances within ±0.005 mm. Final inspection includes CMM verification at multiple thermal states.

How does Frigate address erosion in Die Casting Mold Cores caused by turbulent alloy flow?

Frigate selects core materials based on melt velocity and alloy aggressiveness—using H13, 1.2367, or high-speed steel grades. High-impact regions receive localized hardfacing or CrN/PVD coating for improved erosion resistance. Frigate uses flow simulation to predict and reinforce vulnerable core surfaces. This improves performance in aluminum alloys with high silicon content.

How does Frigate reduce soldering and sticking issues on Die Casting Mold Core surfaces?

Frigate finishes critical surfaces below 0.3 μm Ra and applies nitriding or TiAlN coatings to minimize metal adhesion. Surface topography is optimized to disrupt metallurgical bonding between core and alloy. Material pairings are selected based on casting alloy to reduce chemical reactivity. This approach minimizes cycle interruptions and die maintenance.

How does Frigate ensure proper venting and gas evacuation around Die Casting Mold Cores?

Frigate integrates micro-vent slots and vented ejector pin systems into the Die Casting Mold Core assembly. Core geometry is modeled to promote laminar flow and minimize air entrapment. Advanced casting simulation validates vent placement before production. This reduces internal porosity and improves casting quality consistency.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

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

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