Die cast manufacturers combine latest technologies and expertise to manufacture custom parts according to the client's requirements. Aluminum and zinc are the two most suitable metals for die casting applications. The manufacturing industry is always looking for ways to cut down costs. To that end, there has been an increase in different casting applications in the recent times. In order to reduce wastage and at the same time provide customized services, die cast manufacturers combine technology and their manufacturing expertise to produce parts tailor-made for the clients.
In the process of die casting, high pressure is applied to a molten metal to force it into mould cavities. Eventually, metal takes the shape and form as required. A wide range of alloys can be used in this process, such as zinc, aluminum, copper, magnesium and lead, etc. Pewter and tin are other less commonly used materials. The commonly used process by the die cast manufacturers includes cold chamber and hot chamber process. They can also be classified as low pressure and high pressure methods. The high pressure method accounts for almost 50% of the total production done in the industries and involves a metal under high pressure. The low pressure method is employed for some special cases only and accounts for 20% of the total production.
The remaining percentage is constituted by the gravity die casting method. Methods such as squeeze and vacuum die casting are rarely used. The molds used in die casting can be of a variety of shapes, wall thickness, sizes and designs and enable the formation of complex parts with ultimate accuracy and surface finish. The dies are mostly made of alloy tool steel and consist of two major parts/halves. The one being fixer die half, and the other being ejector die half.
There are four varieties of dies available:
Single Cavity Die: It produces a single component
Multiple Cavity Die: It produces multiple identical components
Unit Die: It produces a number of different parts all at the same time
Combinations Die: It produces a number of different parts for assemble
It is very important to choose a reputed Die Cast Manufacturer who is well cognizant of the entire production process and knows how to customize it to obtain the final product.
Some general advantages of die casting are:
Cast surfaces have extra smoothness
High accuracy
Longer service life
Higher tolerance
Economical process and widely applicable
Some disadvantages of die casting are:
Limited choice of materials
Initial cost is high
Casted parts become porous
Related Reading: Mould Specification Sheet Die Casting Moulds Design Plastics Injection Molding Companies
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