Structural Die Casting: The Ultimate FAQs Guide

I know you want to learn more about the structural die casting process.

A reason this guide will answer all your questions on structural die casting and other related processes.

So, if you want to learn more, read this guide.

What is ‘Skin Effect’ in Structural Die Casting?

The Structural Die Casting mechanical properties are acquired from a series of tests carried out on the component.

The metal on the structural die cast surface quickly solidifies and forms a compressed structure with fine grain.

Its strength is higher compared to the underlying metal and this is what can be described as the ‘skin effect’.

Besides, the skin has an inward extension of around 0.38-0.50mm thus rapid solidification results in porosity concentrating to the center section.

The skin becomes comparatively free of porosity. This affects the mechanical properties of the Structural Die Cast.

What is Structural Die Casting?

This is the process of creating complex components by forcing molten metal into molds that are called Dies under pressure. The molten metal then solidifies into a cast.

It is mostly applied in the automotive and aviation industry to make complex parts that are eventually joined together.

A Structural Die Cast

A Structural Die-Cast

What Are The Industry Applications Of Structural Die Casting?

Structural Die Casting is utilized in many industries that require a structural component to be manufactured from metal.

The structural components can be designed for the construction industry but the vehicle and airplane parts are the most structurally die-cast components.

Automotive Industry

Structural Die Casting is used in the automotive industry to produce structural components used in the assembly of cars.

Most of these components are manufactured using high-grade Aluminum alloys.

This is because their major physical trait is their lightweight and they have a very high quality.

They also have exceptional strength hence they eliminate the need for heat treatment.

Aerospace Industry

Structural Die Casting is the most preferred in the aviation industry because the components produced are lightweight.

They are also durable and strong with extreme precision and a consistent manner of production taken into consideration.

Construction Industry

The construction industry requires Structural Die Casting to create precise components which are strong and lightweight.

They also have a special dimension that is tightly controlled making them an asset for architectural projects.

Structural Die Casts Are An Asset In Coonstruction

Structural Die Casts Are An Asset In The Construction Industry

How Is Precipitation Hardening Applied In Structural Die Casting?

Structural Die Casted parts that are made of alloys that are heat-treatable can undergo precipitation hardening.

If the speed of mold filling is slow, gases are prevented from escaping hence they are trapped within the mold.

Annealing has to be carried out on the cast parts based on a time-temperature profile which relies on the dimension and alloy of the part used.

This leads to the generation of a solid solution that is homogenous on the cast part.

After annealing for some time, the cast parts are satiated in water, and in selected cases, they are re-annealed again.

After this solution annealing, alloying atoms are used to supersaturate the solid solution.

During the whole of the Precipitation Hardening, the microstructure’s mechanical strength and hardness are amplified.

This will lead to an increase in the size of the cast parts.

How Does Hot Chamber Compare To Cold Chamber in Structural Die Casting?

The difference between these two is the manner in which the molten metal is put inside the mold while preparing a Structural Die Cast.

Hot Chamber

It uses alloys that contain very low melting temperatures placed in a die containing a movable and fixed section.

A holding pot that is open and joined to the furnace is used to hold the molten metal.

A plunger is then used to take the molten metal into the mold via a gooseneck.

The molten metal will then freely flow into a shot chamber with the die in an upright position.

The mold two halves are closed under pressure for the mold to form with the plunger still down until the metal cools.

A system of ejection shoves the casting out after solidification from the two die halves.

An Illustration Of the Hot Chamber Structural Die cast

An Illustration Of The Hot Chamber Structural Die-Cast

Cold Chamber

A cold chamber refers to its temperature after the introduction of molten metal inside it.

The camber is usually at normal room temperature prior to the pouring of the molten metal inside it.

The metal alloys used have a very high melting point and are heated separately in a furnace and poured into a shot chamber in the die.

The die consists of both fixed and movable sections.

The molten metal alloy is poured vertically and pressure is exerted to force it forward.

The ram sustains the pressure until the molten metals solidify and cool down ready for ejection.

A Cold Chamber Process

A Cold Chamber Process

What Are The Common Types of Dies Used in Structural Die Casting?

There is a variety of dies that have been developed for Structural Die Casting.

They are ever-changing due to evolving technology.

  • Single Cavity – they generate a single unit at a time and are utilized in machines that are limited to handling one die. Limitations are brought about by the die size, the force locking it, and short height.

It is preferred for complicated components that contain multidirectional features within them.

  • Multiple Cavity – they have the ability to generate very many parts of a similar component in a single casting. They are specifically designed for an exact component.
  • Combination – this is a die containing multiple cavities within it. They produce a variety of parts that fit onto each other instead of casting individual structural components.
  • Unit – these are dies that can be placed inside other dies. This unit die is varied for various components while maintaining the large die at a fixed position.

How Does Impact And Dent Resistance Affect The Structural Die Casting?

The Structural Die Castings’ impact and its resistance to dents have been put to test in many four-wheel drive cars in rugged terrain.

Power tools that are hand-operated and are medium-sized Structural Die Castings also display similar characteristics.

The dent resistance of a component is its capacity to endure an impact load without deforming permanently.

If Aluminum is used for Structural Die Castings, the designer can achieve components with very high dent resistance.

This is because of the low modulus of elasticity of its alloys and its moderate to high yield strength when matched with steel or iron.

What Are The Design Advantages Of High-Integrity Low Porosity Structural Die Casting?

The advantages include:

  • They exhibit amazing strength combined with ductility in many alloys.
  • The structural components are very lightweight especially automotive parts.
  • No deformations or blistering observed after welding and heat treatment
  • Gas entrapment is greatly reduced.
  • Lead to reduced production delays due to low impact.
  • That has good precision control for individual components.

What Are The Factors Affecting The Quality of Structural Die Castings?

The following factors affect the Structural Die Casting qualities:

Die Casting Design

The designer has to comprehend fully the requirements of the user and components working conditions.

Using this and other factors like die casting stress, appropriate material is chosen with knowledge of its die-casting performance.

The design structure of the structural die casting should be as simple as possible but meet the design requirements.

Having a uniform wall thickness prevents defects like shrinkage porosity, air holes, and deformations.

Machining Accuracy And Die Structure

Dies are used to making Structural Die Castings therefore their design and material selection greatly influence the product quality.

Having an unreasonable die structure will result in poor product quality no matter what mitigation measures are taken.

The die material also impacts the shelf life of the die and its quality including the process accuracy.

Other factors affected are the trace processing, the roughness of the surface, and the dies improper final assembly.

Shrinkage Of Casting Materials

A Structural Die Castings material shrinkage is usually chosen by giving it as a percentage with a definite change rate.

High-precision die castings require special attention when designing the mold.

A test mold can be created first then the data acquired is used in the components mass production.

There Are Factors To Consider During Design Of Structural Die Cast

There Are Factors To Consider During The Design Of Structural Die Casting

What Are The Pros And Cons of Structural Die Casting?

Structural Die Casting comes with a lot of advantages making it very popular in the industry.

It also comes with its fair share of disadvantages.

Advantages Of Structural Die Casting

  • Complex Details- complex parts can be manufactured in record time with absolute precision and good finishing.
  • Short Lead Time – a normal Structural Die Casting process is usually very brief. The lead time is determined by the properties of the material used and the part size.
  • Excellent Mechanical Properties – Structural Die Cast parts may not be as sturdy as forged parts but they have exceptional mechanical properties. The parts produced have superior conductivity, hardness, and enhanced durability.
  • Superior Finishing – designs can be created to ensure Structural Die Casts have a well-textured and smooth finishing based on the parts requirement.
  • Economical – when it comes to the production of large batches of parts, die casting becomes cheaper due to the reduced cost per part.
  • Excellent Precision – compared to other conventional manufacturing techniques, Structural Die Casting Produces parts with tighter tolerances. This makes it the most appropriate for the delicate application.

How Does Structural Die Casting Impact The Environment?

Just like any other conventional process involved in manufacturing, the environment has to be impacted.

A great deal of energy is required for the melting of metals besides properly treating the wastewater.

Structural Die Casting greatly reduces the eventual environmental impact by utilizing a lot of recycled materials.

This means that a very little energy-intensive is used to produce the cast parts.

The components are also light with thin walls thus reducing the consumption of fuel on vehicles and aircraft.

What Are The Geometric Features of Structural Die Casting?

The Design Geometry of Structural Die Casts determines the process of filling and cooling of parts together with porosity, grain and stress.

The type of metal used for casting determines the level of stress and the grain structure of the part.

The Geometric Features involved in Structural Die Casting include:

Fillet Radii

Fillet radii redirect the concentration of stress at sharp interior corners thereby making the part stronger.

The weak points are reduced by distributing the stress over the fillet’s broader volume, therefore, preventing it from cracking.

Fillet Radii

Fillet Radii

Holes And Windows

The Holes and windows in a structural die cast need the greatest amount of drafting because of the connection they make with the die surface.

The effect is difficulty in ejection with the possibility of blocking the molten metal flow.


Drafting can be described as an angle that varies with the surface and type of Structural Die Casted Wall.




Ribs serve the purpose of assisting the cast metal to wholly fill the crevices of the die casting.

They facilitate the path of the molten metal and fasten the ejection while simplifying it.

Parting Line

Parting Line is where both die halves meet and it outlines the interior and exterior surfaces.

The parting line also decides which cover side becomes the die and the ejector.

Parting Line Of A Die cast

 Parting Line Of A Die-Cast


These are points of standoff and mounting found in the Structural Die Castings.

They assist in sustaining a wall thickness that is even and eliminate the machining done after casting.

How Does A Component’s Operating Temperature Affect Its Structural Die Casting Process?

The operating temperature of any Structural Die Casting is always a limiting factor when it comes to its material selection.

This notwithstanding, such parts still satisfactorily function in as much the temperatures are prohibitive.

Having an initial prototype can be very effective since the design can be optimized before production. This will also help in the appropriate material selection.

What Are The Different Variations of Structural Die Castings?

Many different variations of Structural Die Castings have been produced to counter any errors and deformities.

They also overcome the design flaws and any other issue arising from the Structural Die Casting Operations.

The variants include:

Pole Free

Before the molten metal is poured or injected, oxygen is used to fill the dye cavity.

The oxygen immediately combines chemically with the hot metal immediately it enters the cavity to prevent gas bubbles.

Low Pressure

With this type of Structural Die Casting, the chamber containing molten metal is located beneath the die.

The intake port is used to push it through into the die chamber while maintaining the pressure till solidification.


Acurad is an anagram that stands for accurate, reliable, and dense.

It faster cycle times by merging directional solidification with stable fills.

The procedure involves fill and flows modeling, squeezing indirectly, castings that are heat-treatable and thermal analysis.

After partially solidifying, double pistons raise the pressure on the cast part.

Acurad Structural Die Casting

Acurad Structural Die Casting


This procedure involves pouring the semi-solid metal, swirling it, and taking it to a shot sleeve to be forced into a mold cavity under pressure.

It generates parts with a fine microstructure, outstanding surface finishes, and impeccable dimensional tolerance.


A permanent Die is filled completely with molten metal by pouring it directly into it.

This involves foaming, turbulence, and oxidation with the die being tilted, vertical or horizontal.

Characteristics of Structural Die Castings using gravity are good stiffness, very high strength with good quality.


This labor-intensive method is also called lost wax casting and entails using a wax prototype to shape a mold.

It is then dipped in some liquid ceramic and after the wax hardens, it is melted away.

Molten metal is then used to fill the cavity of the ceramic.

This ceramic will be broken away Immediately after the casting of the metal is removed.

What Is The Importance Of Geometry Planning In Structural Die Casting?

Structural Die Casting design geometry controls the filling and cooling of parts and how their porosity, grain, and stress are impacted.

Some of the defects prevented by geometry planning include:

  • Part finishing
  • Poor fluid life
  • Checks performed post-casting
  • Solidification problems
  • Hot cracking

 How Does A Structural Aluminum Die-Cast Compare To Permanent Mold Alloy Of Similar Composition?

The rate of cooling that comes with Structural Die Casting is very high compared to that of permanent mold casting.

This is because permanent mold casting uses insulated coatings instead of pressure on the metal dies.

Structural Aluminum Die castings have a very fine microstructure compared to permanent mold castings.

Its mechanical properties are also superior including its ductility.

How Can Structural Die-Cast Defects Be Minimized?

Each Structural Die Casting defect has to be individually handled for efficient solution:

  • Strict Quality Control: Porosity is the major defect in Structural Die castings and cannot be completely eliminated from casting. Each production stage has to undergo rigorous quality control.
  • Use Lubricants: Additives can be used when melting the metal to release gases that have dissolved in it. Adding lubricants with each casting stage decreases the odds of porosity being induced on the surface.
  • Appropriate Injection Speed: excess injection speed coupled with improper designs bring about metal turbulence while it is flowing. The Mold is precisely designed with shot speed determined after carrying out mold flow analysis.
  • Improve Die and Part Design: poor designs can lead to shrinkages while cooling. Design hot spots can be removed and runners and gates added to mitigate this.

What Is The Relationship Between Structural Die-Cast Quality And Mold?

The main tool for Structural Die Casting is the die and when designing it, its general structure and that of die parts should be reasonable.

It should be easy to manufacture and use while maintaining safety and stability.

It should be able to prevent the Structural Die Casting component from deforming and allow easy flow of the molten metal within it.

The capacity of the equipment being generated determines the number of cavities within the die.

The temperature of the die casting also plays a major role in the quality of Structural Die Castings.

Unsuitable temperatures of the mold affect both internal and external qualities such as the porosity of the die castings.

At Inox, we will help get high-quality structural die-cast parts and components.

Contact us now for all your structural die-cast parts.

Scroll to Top