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Views: 201 Author: Wendy Publish Time: 2023-04-28 Origin: Site Inquire
In comparison to investment castings and other metal molding castings, aluminum die casting has an advantage because it can create precisely shaped, light-weight components with highly effective strength-to-weight ratios. For parts that are created through die casting aluminum alloys, the wall thickness of cast components generated with zinc can potentially be as thin as 0.3mm.
Die cast products have better mechanical properties. As the liquid metal solidifies under great pressure, it appears fine, dense, and crystalline. The stiffness, hardness, and strength of die cast parts are quite high. In addition, they provide greater conductivity and durability.
Die casting creates components with excellent dimensional precision and durability. Over time, the components retain their dimensional correctness even when subjected to challenging circumstances. Die casting is therefore used to create intricate and internal machine components that must meet high requirements of precision and accuracy.
In comparison to other casting techniques, die casting maintains finer tolerances. In other words, there are little differences in the pieces generated. According to GB/T 1800-2009, the usual tolerance class for die castings is IT13–IT15. Greater accuracy can be reached at IT10W 11. As a result, die casting's outstanding dimensional precision reduces the requirement for machining and maximizes the use of the alloy.
Die components that are cast have a crystalline surface that is uniformly smooth. Molten metal alloy is used in the die casting process to fill the molds and produce precise shapes. Therefore, the parts will be fine and smooth provided the die is well-shaped and the process is in good working order.
Making glossy components reduces the need for further post-processing steps, with the exception of unique requirements. Additionally, after die casting is complete, goods can be sent out for delivery. This may shorten the length of the the whole production cycle.
Die-cast components frequently need less machining than other parts since the surface of die castings is frequently smooth and has great mechanical properties. Sometimes there is absolutely no machining. As a result, spending on auxiliary activities is reduced as well. Die casting's ability to significantly reduce post-processing expenses contributes to its cost-effectiveness.
Notably, the purchase price of die casting machines, molds, and supporting equipment is high. However, mass manufacturing helps with more efficient cost distribution throughout the production process, making the die casting method more cost-effective.
In the die casting process, molten metal rapidly fills the mold cavity at high speed, but the cavities lack gas permeability. Hence, gas bubbles that affect the structural integrity of fabricated parts tend to get trapped within castings.
The presence of gas cavities in die castings would affect such parts when exposed to harsh conditions, such as hardening by heat treatment. Additionally, such parts are predisposed to machining difficulties. Therefore, the machining allowance of the parts should be kept minimal. If not, the hardened layer on die casting surfaces would be removed, thereby exposing the surface.
Generally, die casting is perfect for non-ferrous metals with lower melting points than ferrous metal alloys. However, the process supports ferrous alloys like iron and steel. Ferrous metals have very high melting points and low corrosion resistance, which causes low die life. Therefore, manufacturers always choose non-ferrous metal alloys for die casting.
Moreover, casting ferrous metals come with lots of complexity and several unforeseen complications. Consequently, manufacturers stick to non-ferrous metals only for die casting operations.
Die casting is not a practical choice for low volume production, because the tooling cost of die casting machines and maintenance are quite expensive. Therefore, the process is costly and seems complex for small-scale production.
However, large-scale production becomes cost-effective as costs are well distributed over the many items produced. Suppliers don’t recommend die casting services for low-scale projects, as the process appears to be more expensive than other production methods.
High melting point metals and alloys compromise the effectiveness of steel dies. These metals, like copper, have extensive requirements to resist thermal deformation. The continued presence of alloys with high melting points strains the molding die, thereby reducing its durability.
Unlike other casting processes, the casting machine, the dies, and other related equipment for die casting are costly. Without the essential equipment, it is impossible to carry out die casting. Although cheap materials like zinc are used to cut costs, the overall production process is still expensive. The only time die casting becomes cost-effective is in large volume production.
