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Auto Parts Series
ELECTRIC PARTS SERIES
OTHER DIE-CASTING SERIES
PARTS 3D MODEL
PIPE AND JOINT SERIES
POWER TOOL SERIES
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, aluminum, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small to medium-sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
Two variants are pore-free die casting, which is used to eliminate gas porosity defects; and direct injection die casting, which is used with zinc castings to reduce scrap and increase yield.
Cast Metals
The main die casting alloys are: zinc, aluminum, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: Zamak; zinc aluminum; aluminum to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium. The following is a summary of the advantages of each alloy:
Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
Aluminum: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.
The material used defines the minimum section thickness and minimum draft required for a casting as outlined in the table below. The thickest section should be less than 13 mm (0.5 in), but can be greater.
Advantages of die casting:
- Excellent dimensional accuracy: Typically 0.1 mm for the first 2.5 cm (0.005 inch for the first inch) and 0.02 mm for each additional centimeter (0.002 inch for each additional inch).
- Smooth cast surfaces: Ra 1–2.5 micrometers or 0.04–0.10 thou rms.
- Ability to cast thinner walls compared to sand and permanent mold casting, approximately 0.75 mm or 0.030 in.
- Capability to cast-in inserts like threaded inserts, heating elements, and high-strength bearing surfaces.
- Reduction or elimination of secondary machining operations.
- High rapid production rates.
- Achievable casting tensile strength as high as 415 megapascals (60 ksi).
- Suitable for casting low fluidity metals.
Disadvantages of die casting:
- High capital cost associated with die casting equipment and dies
- Requires large production volume to be economically viable
- Limited to high-fluidity metals
- Casting weights typically between 30 grams (1 oz) and 10 kilograms (20 lbs)
- Final castings may have some porosity, limiting heat treating and welding options
- Not suitable for parts requiring hardening processes like through-hardening or case hardening
