Do you know what die casting is? Actually, it is a metal manufacturing process wherein the molten metal is placed in a molder. In this way, you can instantly achieve the metal shape that you want. Nowadays, this type of processing is commonly used in industrial, automotive, electrical, and even in households. Here, we will give you some of the advantages and disadvantages of die casting. At the same time, we will also be comparing it with other types of manufacturing processes.
Advantages of Die Casting
Best for Mass Production
Die casting products are produced by using die-casting molds. This means that you can easily accomplish your specific shape and tolerance. This is perfect if you are in need of several identical castings. Additionally, there is little or no machining needed at all, making them perfect for mass production.
Precision and Stability
With die casting products, you can always assure that they are durable and dimensionally stable with close tolerance. They are heat resistant too!
Strength and Weight
Compared to plastic injection moldings, die-cast products are much stronger. In fact, thin-wall castings are more durable and lighter than those products made from other casting methods. The best thing about die-castings is that they do not include other parts that are welded or fastened together. This means that its strength is only from the alloy instead of the joined parts.
Disadvantages of Die-Casting
Die-casting is not applicable to all types of metals and alloys. Keep in mind that die-casting will require dies, machines, and other equipment, which are expensive. It could be costly if you are only producing a small quantity. Die-casting will require some extreme precautions for the elimination of the air from the die cavity so that it can’t result in porosity. Die-casting prototypes cannot be achieved if the product is still in the development process.
How Die-Casting Differs from Other Products?
Forgings
In comparison with forgings, die-casting can create complicated shapes that are not forgeable. Also, die-castings can be made to close dimensions and thinner sections as well as coring that cannot be attained in forgings. However, forgings are thicker and stronger compared to die-castings. They also include properties of wrought alloys. Forgings can be created from ferrous and other metals, and additionally, in unique sizes that are not appropriate for-die castings.
Plastics Injection Moldings
In comparison with plastic injection moldings, die-casting products are proven to be more stable dimensionally, more solid, more heat resistant, and even more excellent than plastics when it comes to its cost and properties.
Die-castings have a high level of stability than plastics. Additionally, they can resist ultra-violet rays and other elements. Also, the manufacturing process for generating die castings is much quicker compared to plastic injection moldings.
On the other hand, plastics are less expensive on a per-unit basis. They also have natural color properties which means that finishing is not needed anymore. Plastics are excellent electrical insulators and are temperature sensitive.
Usually, one die casting is all you need, rather than numerous stampings. Die-casting products need fewer assembly operations. And they can be created in close dimensional limits. However, stampings can be created from steel and alloys which are not possible with die-casting. Stampings can be done quickly and are much lighter compared to die castings.
Sand Castings
Die castings only need less machining compared to sand castings. With die castings, it is possible to have numerous holes, thinner walls, produced more quickly and held in closer dimensional restrictions. For every casting produced, new cores are not needed. Die-cast also have smoother surfaces and only requires lesser labor cost.
On the other hand, sand castings can be created from ferrous metals and non-ferrous alloys, which are not appropriate for die casting. They have a greater maximum size and lesser tooling cost. If you only require a lesser quantity, then it can be generated more economically.
If you have any die casting projects, don’t hesitate to contact SEI Castings. Call us now at (408) 374-1031 and we will provide you with quality products and excellent services. We can produce various products in aluminum and zinc alloys. Regardless if you require a small or large quantity, we can produce it for you.