Die casting is a process in which die cast manufacturers produce metal products. The process includes pouring molten metal into molds designed for the project.
Advantages of Die Casting
Other manufacturing processes often have a higher cost than the die casting cost due to the production method. The cost of die casting is reduced due to many factors, including:
- the combination or multiple parts into one, making assembly operations unnecessary
- minimal secondary operations due to the creation of complex net shapes when casting a part
- lower labor costs and simplified stock control
Other benefits of aluminum or zinc die casting include fast production times, fewer steps involved in the process, less material scrap, variable wall thicknesses, and a long tool life.
Die Casting Materials
The three main alloys used in die casting are aluminum, magnesium, and zinc. These materials are used due to their varying mechanical properties. Additionally, they can withstand extreme heat and are completely recyclable.
The benefits of aluminum, magnesium, and zinc die casting also include corrosion resistance, electrical and thermal conductivity, and high strength and hardness.
The Die Casting Process
The first step in the die casting production process is the creation of the mold. The steel mold is created in two or more sections. One section is mounted in a stationary manner and the other is arranged so that it can be removed.
The mold sections are inserted into the machine and molten metal is injected into the die cavity. After the metal solidifies, the mold is separated and the casting is removed.
Hot vs Cold Chamber Machines
Hot chamber machines are used for zinc or other alloys with low melting points. The process of using a hot chamber machine starts with the injection mechanism being submerged in molten metal. A port then opens, allowing the molten metal to fill the cylinder. This process is very fast, having cycle times that can be less than one second.
Cold chamber machines are used for alloys with high melting points and the process is slower than the hot chamber process. The molten metal is poured into the chamber, rather than the mechanism being submerged.
Die casting is the fastest known process for producing non-ferrous metal parts. It can be used to create a variety of products, and you can speak to a die casting manufacturer to find out which alloy and process is best for your product.