About Die Casting

DIE CASTING:

Die Casting is a versatile process for producing engineered metal parts by injecting molten metal under high pressure into reusable steel molds. These molds, referred to as ‘dies’, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

A complete die casting cycle can vary from less than one second for small components weighing less than an once, to more than two minutes for a casting of several pounds. This makes die casting the fastest technique available for producing precise, non-ferrous, metal parts.

Refinements of the die casting process, has expanded casting applications into almost every known market. Today’s die casters can produce parts in a variety of sizes, shapes, and wall thicknesses that are strong, durable, and dimensionally precise.

Die Casting is an efficient and economical process, offering a broader range of shapes and components than any other manufacturing technique. Parts have a long service life and may be designed to complement the visual appeal of the surrounding part. Designers can gain a number of advantages and benefits by utilizing die cast parts.

PROCESS COMPARISON:

FORGING: Compared against forged parts, Die castings can be more complex in shape, as well as being held to closer tolerances.

EXTRUSIONS: Unlike extrusions, die castings can be produced more quickly as well as creating features on many sides in one operation. Casting produces less waste and saving on machining costs.

PLASTIC INJECTION: Compared against plastic injection, Die cast parts are more rigid, dimensionally stable, and much more heat resistant. In chrome plating applications, castings allow for much better bonding than most plastic polymers.

STAMPING: A stamped object with many directional features may require several conjoined pieces to make one whole, where as a die cast part may contain directional features of great variety within one part. In this way, die castings offer the same product with fewer assembly operations and therefore a lower price. Die castings may also offer changes in thickness and form that is not producible in stamped form.

SCREW MACHINING: By comparison, Die castings are made more rapidly and involve much less waste during production. You may cast shapes that are much more difficult or even impossible to achieve through bar or tubular stock, as well as requiring fewer machining operations.

SAND CASTING: Contrasted against Sand Castings, die cast parts require fewer machining operations, and may be made with thinner walls. Die castings also offer dramatically more accurate cast dimensions, and are produced more rapidly. Dies need replacing less frequently than sand casting molds and involves much less labor per cast part.

PERMANENT MOLD CASTINGS: Die casting can offer tighter dimensional accuracy while casting holes. Parts are produced more rapidly and with less labor. Parts have smoother surface finishes and are generally less expensive per casting.

COMPARISONS OF FOUNDRY CASTING METHODS

CASTING METHOD COST PRODUCTION QUANITIITIES MECHANICAL PROPERTIES SURFACE FINISH LAMINATIONS DIMENSIONAL ACCURACY MINIMUM SECTION THICKNESS INCH
PRODUCTION EQUIPMENT UNIT CASTING CASTING SIZE ALLOY
Green Sand Low High Medium Medium Fair None None Fair 1/8
Baked Sand Medium High Medium Medium Fair None None Fair 1/8
Shell Mold Medium Medium Medium Medium Good To Medium MediumTo High Fluidity Good 3/32
Gravity Permanent Mold High Low Medium To Large High Good To Medium MediumTo High Fluidity Very Good 1/16
Low Pressure Permanent Mold High Low Medium To Large High Good To Medium MediumTo High Fluidity Very Good 1/16
Die Casting Very High Low Medium To Very Large Medium Excellent To Medium High Fluidity Excellent 1/32
Centrifugal High Low Medium Medium High Good Limited By Shape None Good 1/8
Investment Medium High Medium Medium Excellent Small High Fluidity Excellent 1/32 to 1/8
Plaster Medium High Small To Medium Medium Excellent Small High Fluidity Excellent 1/32 to 1/8

While the technical information and suggestions for use contained herein are believed to be accurate and reliable, nothing stated in this bulletin is to be taken as a warranty either expressed or implied. It is the user’s responsibility to determine suitability and fitness of application,perferably through independent prototype castings and field evaluation programs. ADAMs Die Cast Inc.’s limited warranty provides only that itscastings will meet its chemical specifications. There is no warrranty of merchantability or fitness for use, nor any other warranty eitherexpressed or implied.

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