Die casting is a manufacturing process that uses specific steel molds. Once the molten metal is poured into these molds, it can create a unique metal part with a precise dimension and smooth or textured surface. These molds are created from steels and are uniquely designed for every project.
The good news is these molds can be used over and over again. Regardless of how many times you have used these molds, you can still obtain maximum accuracy. Some of the most typical die casting alloys that can be used are magnesium, aluminum, and zinc.
What are The Benefits of Using Die Casting?
Some individuals or companies would use die casting over other types of manufacturing processes because of its numerous benefits. First of all, die casting can provide you with great savings. This includes the overall production cost.
When you are die casting parts, there are only minimal operations needed. The complicated internal features, as well as its external threads, can be done in a single process. At the same time, numerous parts can be combined into one. This can lower labor costs and eliminates the process of assembly. Ultimately, you can achieve a consistent component.
You can also enjoy quicker production times with lesser steps right from the start to the finished product. The part that will be produced from die casting will have closer tolerance and its thickness will be more flexible. Die casting can also help in decreasing material scraps. You can guarantee that the part can last longer, most especially if they are made of zinc and magnesium.
What are Die Casting Alloys?
The three major types of die casting alloys that are commonly used are magnesium, zinc, and aluminum. These are the best options because these elements are non-ferrous and have varied mechanical properties which is ideal for any kind of application.
Die casting alloys can resist high operating temperatures and corrosion. At the same time, they can also be recycled. Die casting alloys have extreme thermal and electrical conductivity. They also have tremendous strength and stability. By using these die casting alloys, you can expect that your finished product will have an excellent finishing.
Furthermore, each of these die casting alloys provides unique benefits that vary from one another. One of the greatest things about die casting is you are not restricted to your choice of metal.
What are the Different Types of Casting Methods?
Essentially, the die casting process is the method in which molten metal is infused into the steel mold or the die. Die casting machines vary in sizes. But regardless if you are using a small or large machine, the major difference is the method being used in infusing the molten metal into the die. Keep in mind that there are various types of casting methods. Hence, you can choose the best process that is ideal for your specific project.
Cold Chamber Die Casting
This is more suitable for metals that have high melting points. One of the greatest examples would be aluminum. The first step for cold chamber die casting is to liquefy the metal. Afterward, it will be poured into the cold chamber either by using an automatic ladle or a manual ladle. Then the cold chamber will be sealed by a plunger. The metal will be forced into the die by applying high pressures.
Hot Chamber Die Casting
This type of die casting is commonly used for zinc, magnesium, copper, lead and other types of metals which are low melting. This is a more suitable choice for alloys that do not quickly wear down metal plungers and cylinders.
Injected Metal Assembly
In this process, manufacturing costs can be minimized. It is a much better choice than any other type of joining and assembly process.
Likewise, there are other variations on its basic process which are intended for specific casting applications. For instance, squeeze casting is a specific method of casting with no turbulence and gas involved.
Typically, a die casting process can be completed in less than one second for small parts that weigh less than an ounce. However, for components that weigh more than this, it will take two to three minutes to complete the process. This means that die casting is the quickest method for manufacturing accurate metal parts.
What are the Benefits of Die Casting?
Most industries would favor the die casting process because it is economical and efficient too! Consequently, it can produce components in various shapes which is not possible with any other type of manufacturing process. Parts produced by die casting are sturdy and can last longer. Choosing die casting offers several advantages and benefits.
Preciseness and Strength
With die casting, you can always assure that the part being manufactured is sturdy and its dimension is accurate and stable. They can resist heat and corrosion while providing close tolerances.
Even if the parts require close tolerance and complicated shapes, it can still mass-produce at high speed. Numerous identical parts can be produced and most often it does not require any machining at all.
Lighter and Stronger
Compared to plastic injection moldings, parts that are produced from die casting are much stronger. Thinly walled castings are also much lighter. Additionally, it has greater strength since die castings are created as a whole. Unlike other methods wherein the parts are being attached.
Die casting manufacturing process is very versatile since it can provide some of the essential elements needed for its closure including studs. You can add holes and external threads to the die casting parts.
With die casting, you can have several options on its finishing. Your die cast components can either have smooth or textured surfaces. Surface processing can be done easily.
SEI Castings is a leading die caster that uses aluminum and zinc alloys. Whether your project is easy or difficult, our engineers can get it done. We can produce small or large batches, no job is too big or too small. Most of all, we can help you reduce the cost of your product. SEI is an expert in short-run casting products which occurs when the cost of the die is larger than its process.
Short-run casting offers efficiency with regards to minimizing its setup time and costs. To request a quote, just visit our website and take a look at our different products before reaching out to us. For more information, you can contact us at 408-662-4887 or send your message through our website form. We look forward to working with you!