>> Overview
Pressure die casting is great for manufacturing higher volumes of metal parts in aluminium, zinc or magnesium. Industry Proto-mold manufactures high quality die cast tools, offer precision die casting and post process machining and finishing options.Die casting is used for low to mid volume metal part production, production metal parts, complex metal parts.
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>> Die Casting Materials: What are the Metals Used for Die Casting?
Can I die cast any metal that am planning to use?
No, die casting is not suitable for all types of metals. There are some metals that cannot be die-cast because of their physical and chemical properties. Since the process involves the use of heat and high pressure, only a few metals can withstand it.
Before we look at the metals used in die casting, let's look at the two key aspects that determine the choice of metal:
1. Heat: During the die casting process, there must be enough heat to melt the metal. However, this hat should not alter the best characteristics of the metal. This means that the metal’s properties should remain the same despite the high temperatures.
2. Pressure: The metal should still maintain its desirable features despite the pressure that is being exerted on it.
Although there are different die casting techniques, all of them t draw their reference points from these two critical aspects. They will also enlighten you in choosing the right die casting technique for whichever type of metal that you are planning to use.
>> Common Metals Used In Die Casting
Here a is a breakdown of the most common die casting metals;
1. Zinc die casting
Zinc is a very popular metal that has a wide range of applications in the modern world. It has a wide range of applications.
Before you consider die casting your zinc metal, you should have a proper understanding of its alloys. The most common alloys for zinc die casting include ZA alloys and Zamalak alloys.
The good thing about zinc alloy is it can withstand high pressure and temperature. Through this process, this metal and its alloys will be relevant in their respective areas of applications.
2. Brass die casting
Brass is another alloy that can be used in the die casting process. This metal is basically an alloy of zinc and copper.
There are different types of brass alloys. Their difference is mainly because of the different percentage of copper and zinc
Other metal elements can be added to this alloy in order to enhance the desirable characteristics of the brass.
Brass alloys that are used for die casting include Admiralty brass, Alpha brass, Duplex brass, Aluminium brass, Beta brass among others.
One desirable property of brass is easy to machine. Brass metals are easy to die cast. The metal is also highly resistant to corrosion and is known for having extra strength. The low melting point of this metal makes it easy to deal with.
3. Aluminium die casting
Aluminium is among the most common metal that is used in a die casting process. It is also among the oldest metal types that are subjected to this process. It is also cheaper to take aluminium through this process.
Aluminium is known for its physical strength. This explains why it has a wide range of applications.
Die casting aluminium is among the best ways of turning it into a more usable form. The good thing about this metal is can be recycled.
There are different types of aluminium alloys that are used for die casting. They include K-alloy, alloy 383, alloy 413, alloy B390, alloy B360 among others.
Some desirable properties of aluminium that make it a perfect metal for die casting include tenacity, high operating temperature, excellent thermal properties, lightweight among others.
4. Steel Die casting
Steel is another common metal that we die cast. We give it a high priority because it is very versatile. This means that it is used for many different applications.
Being an alloy of carbon and iron, steel has the properties of these two elements. This explains why tends to have numerous superior performance properties.
Other components that make up steel include vanadium, chromium, tungsten among other minerals.
Some types of steel that are used in die casting include; Tool steel, carbon steel, stainless steel and alloy steel.
Some desirable properties of steel that make it ideal for die casting resistance to corrosion, extra strength, lightweight, recyclability, electricity and thermal conductivity.
>> Types of Die Casting
As we have seen, there are different types of metals that are processed through die casting. Since each metal has its unique properties, it is obvious that not all of them can be processed ion the same way.
This makes it necessary for us to have different types of die casting. Also, the difference in the casting method is necessitated by the difference in the desired outcome. You may want to achieve a different level of casting and this is possible if the processing method is different.
There are different types of die casting process that can be used to achieve the desired goals. These are;
1.Pressure die casting
2.Gravity die casting
3.Vacuum die casting
Pressure Casting Technology
As the name suggests, the whole process of die casting is fully dependant on the pressure. This is unlike the gravity die casting process. Pressure die casting is mainly suitable for large scale production.
The external pressure is forced into the mould so that it can change the structure of the molten metal.
There are two main types of pressure die casting. These are;
1. High pressure die casting
2. Low pressure die casting
The difference between the low vs high is the level of pressure that is used in die casting their respective molten metals.
Advantages of Pressure Die Casting
Gets the best mechanical properties; Pressure die casting is usually used when you want to get the best mechanical properties from a metal. These features include smooth finishes and high levels of accuracy.
This explains why it is an idea die casting choice for delicate parts.
Ideal for large-scale production: High pressure is used in applications where you need to die-cast large volumes of metals. It increases the rate of molten metal flow.
Creates the best metal finishes. Pressure die casting crate smooth and refined finishes. This is why the products from this die casting are at their purest forms.
Suitable for delicate metal parts. These are metals that are thin and lightweight
Does not require extra machinery
Easy to control. You can easily control the end product of the die casting process. This can be achieved by simply adjusting the pressure level. You can let it operate at high pressure or low pressure die casting depending on what you want.
Disadvantages of Pressure Die Casting
Pressure die casting is only suitable for large -scale production. The high amount of capital needed for this process makes it unsuitable for cases where you want to process low volumes of metal.
The cost of pressure casting is also high. However, you can mitigate this problem by contracting affordable pressure die casting companies in China. They will be able to get the job done at a relatively lower cost.
How It Works – Similar to injection molding but for metals, a mold tool is first manufactured by HLH’s highly skilled toolmakers and engineers. This is then installed on a die casting press and molten metal is injected under pressure into the tool cavity. The parts can then be finished in a range of ways including powder coating and anodizing.
Die casting is used for low to mid volume metal part production, production metal parts, complex metal parts.
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