Die casting is a process in which molten metal is forced under high pressure into mold cavities. The metal hardens to get a desired shape. In recent times, plastic molded parts have replaced die-casting, as they are cheaper and lighter than die cast parts. Die-casting can be done using a cold chamber or hot chamber process.
Using casting process over others generates many benefits. 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.
Die Casting Advantages
l Economical process that can be used for a wide range of complex application
l Parts have longer service life, dimensional accuracy and close tolerance
l Post machining can be totally eliminated
l A process that can be fully automated
l Mold can be use repeatedly
The materials for die castings are specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys, non-ferrous metals as well. In fact, the ferrous metal is not a good choice. During the producing process, there are some developed methods to ensuring precise surface quality and dimensional consistency. They are generally suited for applications where a large quantity of small to medium sized parts are needed. Though some injection-molded plastic parts have replaced some die-castings of being cheaper and lighter within these years, the hardness and strength still tend to be competitive advantages.
The mold is important as to produce various sizes. But a die's life is most prominently limited by wear or erosion, which is strongly dependent on the temperature of the molten metal. You should choose the suitable metal for the specific dies and operate carefully. Otherwise, the loss would outweigh the gain.
Apart from mold with various sizes, the equipment machines are also important in producing. Basically, there are two major types, hot-chamber machines and cols-chamber machines. The previous one relies on a pool of molten metal to feed the die which equals to the mold. It specifies for the system which include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. And the point that high-melting point metals cannot be utilized and aluminium cannot be used in system should be driven upon much more attentions. However, if some machines include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper and works by firstly melting the material in a separate furnace, a precise amount of molten metal is transported to the cold-chamber machine then.
You need to update the manufacturing procedure because of the development of modernization. And the market expects die casting with high competence.