Die Casting's Processes and Advantages

Update:Dec 22 2016
Summary:

Die-casting is a widely used technique to inexpensively […]

Die-casting is a widely used technique to inexpensively create metallic parts for a variety of applications. The process of die-casting has been in use for hundreds of years, but innovations in techniques and materials have improved the efficiency of the process and the quality of the final product.

Die-casting by pouring molten metal into a die, also known as the gravity pressure method, is a manufacturing method that has been used for hundreds of years. Innovations in the die-casting process led to an explosion of die-casting for many applications in the early 1900's, particularly when zinc and aluminum alloys became more readily available.

Die casting is an economical yet effective process of creating a broad range of shapes. It is considered superior to other manufacturing technique and is considered durable and aesthetic, merging seamlessly with the other parts of the machinery of which it is a component. Die has many advantages and primary among them is its ability to deliver complex shapes with high levels of tolerance than any other mass production methods. Identical castings can be mass produced in thousands before you are required to add any new casting tools.

High pressure die is a manufacturing process in which the aluminum in its molten form is injected with a casting machine under extreme force, speed and pressure into a steel or mold to create parts of the desired shape and design. The rating of casting machines is in clamping tons universally. This rating reflects the amount of pressure exerted on the die. The size of the machine ranges from 400 to 4000 tons.

There are many benefits of using casting process over others. Die casting produces parts with thinner walls, closer limits of dimension and it is possible to speed up the process. Labor and finishing costs are the lowest with die. Complex shapes with closer tolerances can be easily achieved with this process. Unlike forging process, you can cast coring in products created through this process.

Shapes impossible to achieve from bar or tubular stock can be easily achieved with casting. The number of operation processes is less, leading to lower wastage of materials.

Die casting is used when you need parts that are dimensionally stable and durable. They are heat resistant and maintain good tolerance levels which are crucial pre-requisites for any good machinery parts. They are stronger and lighter than parts made by other casting methods. They do not have parts that are welded or bolted together, thereby immensely enhancing their efficacy. Another advantage is the multiple finishing that you can achieve with casting. The surfaces can either be smooth or textured providing ease of application and use.