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Die Casting Advantages And Disadvantages

What Is Die Casting

Die castings are used to manufacture a variety of products. It involves filling the mold cavity with pressurized molten metal. Heat the raw metal and press it into the cavity. After the molten metal has cooled and solidified, a newly formed casting is ejected. Such as automotive lighting. Although die casting is a universal casting process, it has both advantages and disadvantages for manufacturing companies.

Advantages of Die Casting

High production efficiency-the production process is easy to mechanize and automate. Generally, cold chamber die casting machines die casting 50 to 90 times per hour. The hot chamber die casting machine die-casts 400 to 900 times per hour.

Excellent dimensional accuracy and smooth casting surface. The general casting tolerance grade of die castings is IT13~IT15 in GB/T 1800-2009, and higher precision can reach IT10~W 1 1. Surface roughness (Ra) is 3.2 ~1.6 μm, local up to 0.8μ. Generally, the higher dimensional accuracy of die castings is required, and the surface finish is high, which leads to higher costs. Ordinary die-casting parts can avoid the finishing process, improve the utilization rate of the alloy, and save the processing cost.

High mechanical properties of die castings. The metal melt in the die castings cool quickly and crystallizes under pressure, so the crystal grains near the surface of the die castings are fine and dense. Both strength and hardness are high.

Die casting parts can have complex shapes. Compared with sand castings and metal mold castings, the wall thickness of the parts can be smaller at the same time. The minimum wall thickness of aluminum alloy die castings is 0.5mm. The minimum wall thickness of zinc alloy die castings can reach 0.3mm.

Other materials can be embedded in the die castings during the die casting process. Complex fasteners can be included in the final assembly, which saves material costs and processing costs. This complex die casting improves the performance of the part and reduces assembly steps.

Economical and easy to mass-produce. Durable and dimensionally stable die-casting parts can be obtained in the specified shape, so no machining or less machining is required.

Various surface textures-Die casting parts can have many finishing techniques and surfaces. This process can achieve smooth or textured part surfaces.

Disadvantages of Die Casting

Porosity is easy to produce in die casting parts. The metal melt fills the mold cavity at a high speed during the die casting process, and the mold material has no air permeability. Die castings produced by conventional die casting methods are prone to cavitation. Due to the presence of the air cavity, die castings cannot be strengthened by heat treatment and cannot be used at high temperatures. At the same time, the machining allowance of the parts cannot be too large, otherwise, the hardened layer on the surface of the die casting will be removed, so that the surface of the die casting will be exposed.

Not suitable for small batch production. Die casting types are complex and expensive, so they are usually only suitable for mass production. For small-scale production, this is uneconomical.

Some metals (such as copper alloys) have high melting points, high heat deformation resistance, and thermal fatigue strength requirements, so the mold service cycle is short. At present, the materials of die castings are mainly aluminum alloy, zinc alloy, and magnesium alloy. Ferrous metals are rarely processed by die casting.

Huge capital investment. Compared with most other casting processes, it is more expensive for the required casting machines, molds, and related equipment. As a result, to make die casting an economical process, it must be mass-produced.

Compared with Sand Casting

Compared with sand castings, die castings require less machining. Die-cast parts have thinner walls, can maintain a more compact size, and have higher production efficiency when produced in a mold. The surface is smoother and the labor cost is lower. On the other hand, sand castings can be made of ferrous metals and many non-ferrous alloys that are not suitable for die casting. The maximum size can be larger, tool costs are usually lower, and a small number of sand casting parts can be produced economically.

Compared with Investment Casting

Most of the die castings are made of non-ferrous metals such as zinc, aluminum, and magnesium. Investment casting can be cast with non-ferrous metals, including stainless steel. If you want to use a non-metallic material, the machining process provides comparable characteristics. However, if you want to use stainless steel or copper alloys, casting is a better choice.

Compared with Forging

Compared with forgings, the shape of die castings is more complicated, and the shape of forgings is simpler. The thin wall of the die casting is thinner, close to the design size. However, the density and strength of forgings are higher than that of die castings. They have the characteristics of forged alloys. Forgings can be forged from ferrous metals and other metals.

Compared with Stamping

Compared with stamping, one die casting can usually replace multiple parts. Die castings generally require fewer assembly operations. It can be kept in a smaller size range. On the other hand, stamping has the characteristics of forged metal, which can be made of steel and alloys that are not suitable for die casting, and the production speed is faster, and the weight may be less than die casting.

Due to the advantages and unique advantages of the above-mentioned die casting parts, die casting products are now more and more widely used. It plays an important role in many products such as laptops, mobile phones, cameras, cars, and motorcycles. Among these products, die casting parts appear to consumers as fashionable, environmentally friendly, user-friendly, and innovative products, and consumers also highly approve of such products. With the development of die casting technology, die-casting parts will be more widely applied.

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If you would like to have a question then get in touch today, we are ready to assist 24/7.
We welcome your cooperation and we will develop with you.

 Factory-direct Connectivity Solutions.
 High quality, Competitive Price.
 Custom-tailored solutions.
 Problem-solving approach.