Die casting is a type of metal casting that uses the process of forcing molten metal into two steel dies that make up a cast. Die casting is typically used in a high-volume production setting and is known for producing a high-quality, consistent product. The equipment used for the die casting process typically has a higher initial cost compared to processes that use sand molds. However, the day-to-day cost of manufacturing using die casting tends to be on the lower end, producing a lower cost per item.
Advantages of Die Casting
Precision and Complex Geometry
By utilizing the high-pressure die-casting process, you can create precision-engineered components with complex geometries that are critical for a variety of applications, such as electronic housings, gearboxes, pumps, valves, connectors, brackets, and more.
Cost-Effectiveness
Die casting offers significant cost advantages to the agricultural, construction and mining machinery industries, especially compared to alternative processes such as plastic injection moulding, welded parts or sand castings. Die casting enables the production of high-volume parts at a relatively low unit cost.
Strength and Durability
Agricultural/construction/mining machinery and equipment are subject to harsh operating conditions and heavy workloads. CWM uses durable alloys such as aluminum, magnesium, or zinc, which provide exceptional strength and longevity. These alloys offer high resistance to corrosion, weathering, and wear, ensuring that components withstand demanding environments and continue to function reliably.
Lightweight Design
Efficiency and mobility are crucial in modern agriculture. Die casting allows for the production of lightweight components without compromising on strength. The lightweight nature of die cast parts helps reduce the overall weight of equipment, leading to improved fuel efficiency and reduced soil compaction.
Environmental Considerations
Sustainable agriculture practices are gaining prominence worldwide. Die casting aligns with these practices as it promotes environmental sustainability. Because die castings are produced from 100% recyclable alloys, they contribute to more environmentally friendly agricultural/construction/mining practices.
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Design Considerations in Die Casting
Draft
A draft angle is a slope integrated into the die mold’s vertical directions to facilitate easier part ejection. However, the angle depends on the casting material, surface finish, wall thickness, and geometric complexity.
Avoiding the draft angle during the mold design will cause the part to stick/drag on the die mold during ejection. Consequently, it can damage the part and/or the mold. Incorporating a larger draft angle will increase material usage and manufacturing costs.
Generally, a draft angle of 10 to 20 will improve part ejection. For typical aluminum die casting, the recommended draft angle is 20 per side to accommodate the material’s abrasiveness. Zinc, on the other hand, has a shrinkage rate of 0.7% which you can accommodate in the tool design.
Fillet Radii
Fillet radii are important in part designs where you cannot avoid sharp corners. They reduce stress concentrations at sharp corners, by distributing it evenly throughout the part. The fillet radii depend on the part geometry, casting material, and functional requirements.
A minimum fillet radius of 0.4mm is recommended but is limited to 0.8mm. A large fillet radius will reduce stress but increase material usage and machining costs. On the other hand, a smaller fillet radius may not provide sufficient stress relief.
Parting Line
The parting line is the line where the two mold halves meet. Ensure the parting line is straight. Furthermore, it must be located and orientated to minimize its visibility and not affect part functionality. Factors like part geometry, undercuts, draft, and gating can influence the parting line placement.
Bosses
Bosses are a feature added to a die-cast that serves as mounting points. They should have a universal wall thickness for maximum strength. When choosing a boss, consider its diameter, height, and wall thickness. An oversized or undersized boss can lead to assembling issues, part distortion, or reduced part strength.
Ribs
Ribs are thin and raised features that increase a part’s strength without increasing its weight or material usage and they minimize part deflection and improve dimensional stability. Consider the part size, shape, thickness, height-to-width ratio, and spacing when choosing a rib. Using overly thick or thin ribs can lead to sink marks or warping.
Holes and Windows
Properly designed holes and windows serve as ventilation, drainage, or component integration. Designers should consider the hole diameter, depth, and location during incorporation to prevent part defects or functional issues.
What Materials Are Used in Die Casting
Magnesium
Magnesium alloys are widely used for lightweight and high-strength parts. There are limitations in the processing, but magnesium alloys can achieve among the thinnest sections in die casting, because of very low viscosity in the melt.
Zinc
Zinc is very widely die-cast for many lower-strength applications. Zinc and commercial alloys it is a major constituent of are low-cost, easily cast, and sufficiently strong for many components such as enclosures, toys, etc.
Copper
Copper is not widely used in die casting, as it has a tendency towards cracking. It requires a high melt temperature, creating increased thermal shock in the tooling. When it is die-cast, it requires careful handling and a high-pressure process. For more information, see our guide on Copper.
Pewter
Pewter is a soft alloy, mainly tin, with antimony and traces of copper and bismuth. It is used purely for decorative objects and die casts easily in low-pressure equipment.
Aluminum
Aluminum alloys are by far the most important materials in volume die-cast production. They respond best to a hot chamber and high pressure—or more recently vacuum die casting—and provide moderate to high strength and high precision parts. Aluminum alloys are still critically useful in lower-tech processes, too.
Lead
ROHS has resulted in a significant reduction in the use of lead parts. They, however, remain critically important in the manufacture of (ICE) automotive battery parts, particularly terminals. Much development in lead die casting has improved overall automation and process speeds—developments that have fed through to other materials processing.
Tin-Based Alloys
Tin-based alloys impose very low wear and stress on tools due to low viscosity and melting point. While high-tin alloys (other than pewter) are rarely used now, the need does arise and specialists exist to serve in this.
Steps Involved In The Die Casting Operation
Create Mold
First, computer-aided design (CAD) software is employed to design the die mold. This software allows the creation of a three-dimensional (3D) model of the die mold. Once the design is finalized, the actual die mold can be created. This involves machining the mold from a metal block using a CNC machine. After cutting, the mold usually need to a heat-treating process to harden the mold.
Clamping
Clamping is the initial stage in die casting. To ensure an efficient injection and removal of the solidified product, it's important to lubricate and clean the die beforehand to eliminate any impurities. Once it's clean and lubricated, apply strong pressure to clamp and close the die.
Casting
For the injection of melted metal, it should be poured into the shot chamber. This step varies depending on the process in use. For instance, in cold chamber die casting and hot chamber die casting. It is crucial to note that a high pressure produced by a hydraulic system is necessary for this stage.
Cooling
After the casting has been set, it must be cooled and removed from the mold. This step is essential for maintaining the casting's structural integrity. Manufacturers usually employ forced or natural cooling during this stage of die casting. However, the type of cooling used often depends on the size and complexity of the casting.
Ejection
Following cooling, manufacturers use ejector pins to expel the casting from the mold chamber and remove it from the mold. Ensure that the final product is solid before ejecting it.
Trimming
The final stage involves removing any excess metal that might be present in the sprue and runner of the finished product. Trimming can be done with a saw, grinder, trim die, or other tools. The beauty of the process is that the removed parts can be recycled and reused. During this process, to prevent damage to the casting, one must pay great attention and care.
Types of Die Casting
Gravity die casting
In gravity die casting, gravity causes the molten metal to pour into the mold cavity. The molten metal is prevented from sticking to the metal mold by using a liquid slurry coating.
One mold box contains half of the pouring basin, gate, runners, and cavity, while the other mold box contains the remaining half. When it comes to the core, half goes into one mold box and the other half goes into the other mold box.
Aluminum die casting
A metal forming technique that can produce complex aluminum parts is called aluminum die casting. Aluminum alloy ingots are completely melted after being heated to extremely high temperatures.
The liquid aluminum is injected into the cavity of the steel mold under pressure. After the molten aluminum solidifies, the two halves of the mold separate to reveal the cast aluminum part.
The finished aluminum product has a smooth surface and requires little machining. Due to the use of steel molds, this type of casting is ideal for mass production of aluminum parts.
Pressure die casting
In pressure die casting, molten metal is injected into a permanent metal mold by external pressure. This type of casting can be classified using the following categories:
Cold chamber pressure die casting
Alloys such as aluminum and zinc alloys that contain a large amount of aluminum, magnesium, and copper cannot be used in hot chamber machines. This is where this method comes in.
The process involves first melting the metal in a furnace and then transferring a precise amount of molten metal to a cold chamber machine, which then feeds it into an injection cylinder.
Hot Chamber Pressure Die Casting
The machines used for hot chamber die casting are also called "gooseneck machines." To feed the die, the machine uses a pool of molten metal. A piston in the assembly retracts at the beginning of each cycle, allowing the molten metal to fill the "gooseneck" and begin the cycle.
A pneumatic or hydraulic piston forces the metal out of the gooseneck and into the die. Fast cycle times (approximately 15 cycles per minute) and the convenience of melting the metal inside the casting machine are two advantages of this system.
Die Casting vs Sand Casting – Key Differences
Startup Time
The startup time for these processes can be vastly different. Sand molds can be made very rapidly if the desired pattern is already at hand. Making a steel die for die casting, however, takes longer since it needs to be designed, machined, tested, and affixed to the equipment, which can be very time-consuming.
The setup and required machinery for die casting also mean much larger upfront costs than sand casting. The investment in die casting equipment generally only makes sense for higher production volumes.
Surface Finish
Another difference between sand casting and die casting is the surface finish of castings made from these methods. Sand casting leaves behind rough surfaces on parts because the compacted sand imprints its texture onto the cast. Specialized sands and other measures can reduce roughness, but this comes with extra cost. Die cast products, however, boast a very high-quality surface finish due to both the smoothness of the die' s inner walls and the pressure used to fill the die. Note that designed textures can also be added to die cast parts if desired.
Complexity of Parts
While both methods can create complex part shapes, die casting is often the preferred process for these types of casts. Thanks to pressure injection of the molten aluminum, die casting can make components with very thin walls. The pressure injection also leads to greater dimensional accuracy for cast parts relative to sand casting.
Application of Die Casting
Construction
Because of their strength and lightweight, aluminum metal castings are used to manufacture window frames, roof superstructures, and building frames. Residential and commercial buildings, bridges, and skyscrapers are now made with a variety of die cast parts.
Health Care
Die cast parts are used to manufacture complex medical devices such as ultrasound systems, pacemakers, dialysis equipment, medical robots, monitoring devices, and hospital bed gearboxes.
Energy
The oil and gas sectors are dependent on die casting components to produce piping, drilling machinery, valves, flow controls, filtration devices, impellers, and more. The renewable energy sector utilizes a range of die cast components such as wind turbine blades and solar panel brackets.
Electronics
The rapid pace of innovation in the consumer electronics industry requires a constant supply of flexible, light, heat resistant, and highly durable precision parts. The electronics industry incorporates die cast components in everything from 5G base-station housings to smart phones to drones to personal computers and home appliances.
Culinary
Cast iron and stainless-steel castings are ubiquitous in the culinary industry. Products such as stainless steel and cast-iron pans, skillets, and ovens are used by both the average consumer as well as the restaurant industry. Because it is resistant to bacteria, heat and chemicals, stainless-steel precision casting is widely used for heavy machinery in the food processing sector.
Mining
Die cast metal components are used in mining and mineral processing equipment such as excavators, drills, draglines, crushers, and specialized heavy-duty vehicles.
Paper
Paper mills rely on a range of machinery made with die cast components. These include heads used in paper machine dryers, pulleys, gears, and housings.
Furniture
Die cast aluminum parts can be precision made cheaply from recycled materials, have no joints, can be powder-coated, and feature parts with many integrated functions. This makes them ideal for furniture manufacturers.
Mechanical and Plant Engineering
High-precision manufacturing processes are only possible with the use of large-scale die cast industrial products such as machine tools, conveyors, pumps, lifting equipment, and compressors.
Aerospace
As with the automotive industry, the aerospace sector requires lightweight, high tensile structural components and complex parts. The use of magnesium and aluminum die casting allows aerospace manufacturers to build lighter and more fuel-efficient aircraft.
FAQ
Q: What are the two types of die casting?
Q: How long does a die cast last?
Q: Can die casting be reused?
Q: Is die casting permanent?
Q: What is the coating for die casting?
Q: Is die cast breakable?
Q: What steel is used in die casting?
Q: What is diecast used for?
Q: Is die cast plastic or metal?
Q: Does die cast rust?
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