Die casting is a quick precise process of forming components made from metal.
High pressure die casting is favored, especially, by advanced industries that demand for definite requirements over dimensional tolerances, appearance and lightweight components.
Let’s look at the advantages of die casting:
Advantages Of Die Casting
Die Casting Design
Die casting is an effective, cost-saving method giving a variety of shapes and parts in comparison to any other metal manufacturing process.
Components fabricated through die casting boast of prolonged service life and you may design them to visual allure of the adjacent part.
You can enjoy a number of benefits to your business by opting for die cast parts.
Here are the common benefits of die casting:
Best For Mass Production
It is possible to engineer the dies to construct different sophisticated yet precise shapes because you produce them using die-casting molds.
Thanks to the die casting molds, it is possible to replicate the procedure some thousand times to form flawlessly identical metal casts.
This capability makes high pressure die casting suitable for mass production.
Furthermore, the metal fabrication method is convenient since it requires minimal to no machining.
Accurate, Stable And Long-lasting
The dies should be stronger in comparison to those used in the other molding operation so as to endure the exceptionally high-pressure injections.
Die cast parts are also dimensionally stable and heat-resistant whilst they sustain close tolerances.
Diecasts boast of a higher level of permanence if loaded in comparison to their equivalents.
This makes die casting a better option than the other metal mass manufacturing techniques available.
Tough And Lightweight
Diecasts, even thin-walled types, have strengths far better compared to their plastic peers having similar measurements.
Moreover, since they are one intact piece unit and not an assembly of various parts, die cast parts are expected to be tougher.
The parts depend on the metal alloy strength rather than duration of how components hold together because of joining technique applied during manufacturing.
Supports Variety Of Metals And Alloys
Die casting process supports several different alloys and metals, with zinc being the popular option due to its high strength and ductility.
Tin, lead, aluminum, copper and magnesium are the other alloys and metals that you can process through die casting.
Cost-effective
Die casting process is equally comparatively affordable. This is another reason that makes it perfect for large-scale production applications.
Produces Smooth Surfaces
You do not have to worry over rigid or rough casting surfaces when using die casting.
Because it entails pressurized molten metal, die casting technique forms exceptionally smooth surfaces.
As you force the molten metal in the mold cavity, it fully fills while the molten metal is forced into the cavity of the mold, it completely fills the space ensuring a smooth surface.
Minimal Finishing Operations
Another die casting advantage is the capability to reduce the necessity for finishing procedures.
In other forms of casting processes, the formed products are commonly finished utilizing a machine.
These additional machining procedures can be cumbersome and time-consuming.
Fortunately, die casting minimizes the necessity for such processes.
In most instances, die cast parts are for shipping immediately after the process of die casting.
Can Form Parts Of Different Thinness And Texture
Die cast parts
You can form any shape and finish using die casting molds. This allows you to produce polished, textured, or any kind of surface finish, based on the requirement.
Because of this fact, the die cast parts can be smoother in comparison to other casting types like sand and permanent mold.
Moreover, you can construct thin-walled diecasts that are still durable and dimensionally stable.
Still, you can have perforations that are bored to their sizes, coupled with other capabilities.
Die Cast Product
Simplified Assembly
You can form essential fastening parts, such as bosses and studs, through die casting process. This makes the casting method more affordable, than, for instance, sand casting.
Because nearly no machining is necessary, finishing expenses are negligible, which leads to general savings from the procedure.
Diecasts also need lesser assembling operations, and they can typically serve the role of several components.
This leads to lesser time manufacturing an entire new piece of items or assembly.
Corrosion Resistance
The rates of corrosion for die cast parts are slower in comparison to those of sand castings. This is due to the more polished diecast surface.
Tolerances
Die casting process fabricates complex parts having extremely close tolerances.
Unique Advantages Of Die Casting Compared To Other Manufacturing Methods
There are unique die casting advantages in comparison to other metal fabrication techniques as discussed below:
Plastics Injection Moldings
Die castings are stiffer, more stable dimensionally, stronger and more heat resistant in comparison to plastic injection moldings.
Furthermore, they are exceedingly superior to plastics in terms of properties and cost.
Die castings have greater level of permanence when under load in comparison to plastics.
Also, they are fully resistant to UV rays, stress-cracking and weathering under different environmental elements.
Production cycles in die casting process are much quicker than in plastic injection moldings.
Nonetheless, plastics might be less costly on a piece volume basis.
Plastics also possess color inherent features that tends to do away with the need for surface finishing.
Furthermore, plastic moldings are better electrical insulators and are temperature sensitive.
Sand Castings
Here are the unique benefits of dies castings in comparison to sand castings:
- Die castings need less machining;
- Can be constructed with thinner walls;
- Can have all or almost all perforations cored to size;
- You can hold them within much proximate dimensional limit
- Diecasts are manufactured more speedily in dies that form thousands of units without replacement;
- Die casting process does not need new cores for every casting;
- Are easily offered with inserts diecast in position;
- Have more polished surfaces and entail much reduced labor expenses per casting.
On the contrary, sand castings can be manufactured from many non-ferrous and ferrous metals and alloys not fit for die casting.
Tooling expense is usually less, maximum size may be greater, and you can produce small quantities more economically.
Forgings
In comparison to forgings, you can make die castings in more complex and unforgeable shapes.
In addition, they can have thinner parts, have coring not compatible with forgings, and may be held to adjacent dimensions.
However, forgings are denser and tougher compared to die castings, having wrought alloys properties.
Furthermore, you can produce them using ferrous and other types of metals, in sizes not fit for die castings.
Stampings
Compared to stampings, a single die casting can usually replace various parts. The die casting process often need fewer assembly procedures, and you can hold them in closer dimensional limits.
On the contrary, stampings possess the characteristics of wrought metals, and can be fabricated using steel and alloys not appropriate for die casting.
Also, in their basic forms, you can produce them faster and can weigh less compared to die castings.
For all your die casting processes from China, Inox is here to help – contact us now.