Die-casting is one of the most cost-effective and versa […]
Die-casting is one of the most cost-effective and versatile manufacturing processes in the world from manufacturing replica cars and airplanes to real-life, durable mechanical components.
Die casting is a precision process that involves injecting molten metal into a mold or mold of a desired shape under high pressure. Molds are usually made of durable, high-quality steel. After the material sets and cools, designs that support a complex array of complex geometries and details are ejected for quenching, machining, or finishing.
This process can be repeated again and again with incredible dimensional accuracy, making it one of the best ways to manufacture large quantities of castings.
In addition, some castings can be completely ejected from the mold, eliminating the need for machining and additional finishing. By providing high-speed manufacturing processes, precision and high-quality castings, die-casting has become a valuable manufacturing method since its invention in 1838.
One of the most important choices in casting design is determining the type of alloy that best suits its particular application. Aluminum, magnesium, zinc and zinc aluminum (ZA) are the most common types of metal alloys used in die casting processes.
Each alloy has its own physical and mechanical properties, which are important factors that determine the life, strength and overall functionality of the finished product. Unlike copper or ferrous alloys, the most commonly used alloys have a lower melting temperature, which can affect castability. The complexity of the part, the minimum wall thickness of the part, and the required accuracy will also affect the casting of the part.
Depending on your application of metal alloy for your design and use, there are several different die-casting methods that provide more manufacturing flexibility. These include hot cells, cold cells and squeeze casting processes.
Hot-chamber die-casting is ideal for metals with lower melting points, such as zinc and magnesium, and cold-chamber processes for metals such as aluminum with higher melting points. Squeeze casting is a process that does not require entrained gas to produce high quality parts.