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Cost-Effective for High Volume Production
High Strength-to-Weight Ratio
Reduced Post-Processing
Consistency and Repeatability
Design Flexibility
Die casting is a metal casting process that involves forcing molten metal into a mold cavity under high pressure. The process typically follows these steps:
1.Die Preparation: The die, also known as the mold, is prepared with two halves, a fixed half (die) and a movable half (core), which together form the desired shape of the part.
2.Injection: Molten metal is injected into the mold cavity at high pressure, typically using a hydraulic or pneumatic system. The pressure helps ensure that the metal fills the entire cavity and solidifies quickly.
3.Cooling: Once the mold cavity is filled, the molten metal is allowed to cool and solidify within the mold.
4.Ejection: After the metal has solidified, the die halves are separated, and the finished part, called the casting, is ejected from the mold.
5.Trimming and Finishing: Any excess material or flash is trimmed from the casting, and any necessary finishing operations, such as machining or surface treatment, may be performed.
High Dimensional Accuracy: Die casting can produce parts with tight tolerances and precise dimensions, making it suitable for applications that require high precision.
High Production Rates: Die casting is capable of high-speed production, allowing for the efficient manufacture of large quantities of parts.
Complex Geometries: Die casting can produce parts with complex shapes and features, including thin walls, sharp corners, and intricate details.
Excellent Surface Finish: Die casting can produce parts with smooth surface finishes, reducing the need for additional finishing operations.
Material Versatility: Die casting can be performed with a variety of metals and alloys, including aluminum, zinc, magnesium, and brass.
1.Cost-Effective for High Volume Production: Die casting can be cost-effective for producing large quantities of parts due to its high-speed production rates and minimal material waste.
2.High Strength-to-Weight Ratio: Die-cast parts typically have excellent mechanical properties, including high strength and stiffness, relative to their weight.
3.Reduced Post-Processing: Die-cast parts often require minimal post-processing, such as machining or surface treatment, due to their high dimensional accuracy and surface finish.
4.Consistency and Repeatability: Die casting produces parts with consistent quality and dimensions across production runs, reducing variability and ensuring uniformity.
5.Design Flexibility: Die casting allows for the production of parts with complex geometries and intricate details, offering designers greater flexibility in part design.
1.High Initial Tooling Costs: The upfront cost of tooling (dies) for die casting can be significant, especially for complex or multi-cavity molds.
2.Limited Material Selection: Die casting is primarily limited to metals and alloys with relatively low melting points, which may restrict material options for certain applications.
3.Limited Part Size: Die casting is generally more suitable for producing small to medium-sized parts, as larger parts may require specialized equipment and tooling.
4.Porosity and Shrinkage: Die-cast parts may exhibit porosity or shrinkage defects due to gas entrapment or cooling inconsistencies during the casting process.
5.Long Lead Times: The design and fabrication of die casting dies can take time, leading to longer lead times for new part production.
| Aluminum Die Casting | Zinc Die Casting |
| A360.0 A380.0 A383.0 (ADC12) A413.0 | Zamak 2 (ZA-2) Zamak 3 (ZA-3) |
| Standard (As-Cast) | Oxide |
| Bead Blast | Silver |
| Tumbled | Polyurethane paint |
| Anodized (Type II Or Type III) | Chrome Plated |
| Powder Coat | Gold Plating |
| Chromate | Custom |