One question that manufacturers have to ask themselves when it comes to choosing die casting is do the advantages of the process outweigh the disadvantages. For many manufacturers the answer is yes the advantages of die casting outweigh the disadvantages. The reason behind that is that there is only one or two disadvantages compared to the numerous advantages of this process.
One of the biggest advantages to the die casting process is how many different alloys can be used. Most manufacturers opt for aluminum casting because it is the most cost effective, but there are many other metals that can be used. Other popular metals used in the die casting process include magnesium, copper, lead, tin, and zinc. However, lead is only used in a few industries due to public health reasons.
One of the best things about the die casting process is the fact that it gets rid of the need for any secondary machines; once the part has been cast, it is ready to be used. With other types of casting processes, other machines must be used to add some of the finishing touches, such as inserts or even threads. Die casting is great because the inserts can be done directly inside the mold. For example, if you wish to add threads all one has to do is leave a small space between the threads and the surface to prevent any kind of flashing. However, once the cast is made the threads will be located directly on the casting, no need to use a second machine to make the threads.
Another great thing about die casting in manufacturing is how well the product themselves are made. When manufacturers choose die casting as their method the walls can be thinner than products made from other casting methods and the thinner walls will not compromise the strength or integrity of the part being cast. Not to mention that the dimensional accuracy in the die casting process is the best, especially when it is compared to other casting methods. However, how accurate the dimensions are will depend on the material that is being used for casting. As an added bonus the production rates are so fast they help make up for any disadvantages the process might have.
The biggest downfall to this process, including aluminum casting, is its high capital cost. The reason that die casting has such as high capital cost is because of the equipment, dies, and other components that are needed, they can be pretty costly. While die casting dies have a high capital cost this cost can be offset based on the production volume, the higher the volume is the better. Another disadvantage to die casting are the finished product is porous, so no welding or heating can be done after it has been cats, unless one wishes to damage the finished product. The last disadvantage is that only certain alloys can be used, which are listed above, and the casting weight cannot be less than 1 ounce or more than 20 pounds.