What is involved the die casting process?
Generally, the die casting process involves inserting metal under extreme pressure inside a mold, or a die. Die casting equipment is generally categorized by tons equal to how much pressure the machine can apply onto the die. Die casting machines come in a wide range of sizes, from 400 tons to 4000 tons.
Despite the wide range of sizes, the main difference between the different die casting machines is the approach used to insert the metal into the die. The two approaches used are hot chamber and cold chamber die casting. A complete die casting process cycle can range from not even a second, when developing small parts, to a couple minutes for the creation of several pounds. The die casting process is the quickest method available for developing specific metal parts.
How does the die casting process compare to other processes?
When choosing between the die casting process and plastic molding there are a few things to consider. Die casting is used for creating tougher parts with high tolerances that have strength and endurance. Components made in the die casting process can withstand extreme temperatures.
Another option companies consider is sand casting compared to die casting. Die casting manufacturing creates components with smooth surfaces, thin walls, and close dimensions. Production using the die casting process is also faster and the cost of labor is lower than sand casting.
How do I choose the proper alloy for the die casting process?
Each metal used for die casting provides a different benefit to the component being created.
For example, zinc is the simplest metal to cast. Zinc provides top quality strength and is simple to plate. This ease of use makes zinc extremely cost effective when creating small product components. On the other hand, aluminum is lightweight, but still possesses stability for intricate shapes and thin sides. This alloy is also resistant to corrosion and high temperatures.