Diecasting is one of the most economical and quickest forming processes. The advantages of this production process are that hundreds of thousands of castings can be produced relatively quickly by using just one mold. All components produced have uniform quality and involve relatively low unit costs. But how exactly does the manufacturing process look like? What materials can be used and in what areas are the castings used?
The die casting process is versatile for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called 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.
Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial, and industrial products. Die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.
The die casting process has evolved from the original low-pressure injection method to techniques including high-pressure casting- at forces exceeding 4500 pounds per square inch- squeeze casting and semi-solid die casting. These modern processes are capable of producing high integrity, near-net-shape castings with excellent surface finishes.
Die Casting is an efficient, 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 specifying die cast parts.
Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.
Dimensional Accuracy and Stability
Die casting produces parts that are durable and dimensionally stable while maintaining close tolerances. They are also heat resistant.
Strength and Weight
Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because the die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
Multiple Finishing Techniques
Die cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.
Diecasting provides integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.