ABOUT Die Casting
Technology: Die Casting Services are metal molding operations that produce forms in reusable steel molds usually from low-melt point metals such as aluminum and zinc. In the die casting process, molten metal is injected into the cavities of closed mold halves. After the mold halves are separated, the castings are pushed out from the molds by ejector pins.No expensive sand needed for mold makingLends itself to automationThreaded inserts, etc. can be cast in placeCastings have excellent tensile strengthThinner walls possible than with sand casting
Die casting can produce fairly intricate parts in sizes ranging from about 1 inch to about 30 inches, depending on the capacity of the die casting machine. Because of the cost associated with making the molds, die casting becomes economical only when the production run approaches a moderate volume on the order of 10,000 pieces. Finished parts have smoother surfaces than those produced by sand casting, though sand casting is practical for larger parts and smaller volumes.
Hot chamber machines are used primarily for casting zinc, magnesium, and copper. Cold chamber machines are used for casting aluminum. Cold chamber machines require transfer of the metal by a ladle whereas with hot chamber machines the molten metal is supplied directly to the injection chamber.
Die casting has faster production rates than sand casting because of the reusability of the steel molds. It is a more expensive process, however, due to the cost of the molds and the die casting equipment itself.
Advantages: Die casting produces castings with superior finishes and near net shapes.
Die Casting Limitations Upper and lower limits on part size appliesRequires more expensive equipment and tooling than needed for static castingCastings usually have some level of porosityNeeds high volumes to justify costs
Applications: Die casting is the preferred method for making many small to mid-sized parts in non-ferrous metals. Engine and motor housingsElectrical componentsModels/toys