The advantages of die casting

Die casting is a manufacturing process in which molten metal is poured or forced into steel molds. The molds—also known as tools or dies—are created using steel and are specially designed for each project. This allows each component to be created with accuracy and repeatability. Aluminum, zinc, and magnesium are the most commonly used die casting alloys.

Die Casting Advantages

Die casting has a number of benefits over other manufacturing techniques, and these advantages frequently result in considerable cost savings—both in terms of the part's price and the whole cost of production. Casting a component allows for the creation of intricate net forms, exterior threads, and intricate interior details with no need for subsequent procedures. Additionally, it is possible to merge numerous parts into a single part, removing the need for assembly and so reducing labor costs. This has the added advantages of streamlining stock control and improving component uniformity.

Other benefits include:

Variable wall thicknesses,Tighter tolerances,Fewer steps from raw material to finished part,Fast production cycle times,Reduction in material scrap,Long tool life, especially for zinc and magnesium

Die Casting Alloys

Zinc, aluminum, and magnesium are the three main die casting alloys. They are normally non-ferrous and their mechanical properties vary greatly to fit almost every type of application a manufacturer may need. Not only can die cast alloys withstand high operating temperatures, but they are also fully recyclable. 

Die cast alloys also have:

Good corrosion resistance,High strength and hardness,High thermal conductivity,High electrical conductivity,Outstanding EMI/RFI shielding properties,Good finishing characteristics

Separately, each die cast alloy offers a variety of benefits that the other may not offer. That is one of the great things about die casting, you do not have to be limited when it comes to choosing the right metal.

Die Cast Process

There isn’t one single process that can suit every project. Each project is different which is why Dynacast offers multiple solutions for all die casting needs. This ensures the right process is always used for the right application.

Three different types of die casting processes.

Hot-Chamber

Used for zinc, some magnesium alloys, and other low-melting, hot-chamber die casting is a great option for alloys that do not readily attack and erode metal pots, cylinders, and plungers.

Cold-Chamber

Better suited for metals with high melting points such as aluminum, during cold-chamber die casting, metal is liquefied and then ladled into a cold chamber where a hydraulically operated plunger pushes the metal into the die.

Injected Metal Assembly

Over the past 50 years, we have developed and refined our innovative; one-step manufacturing solution, Injected Metal Assembly. IMA outperforms most adhesives used for small component joining and assembly production and reduces manufacturing costs.