Die Casting Process
The basic die casting process consists of injecting molten metal under
high pressure into a steel mold called a die. Die casting machines are
typically rated in clamping tons equal to the amount of pressure they can exert
on the die. Machine sizes range from 400 tons to 4000 tons. Regardless of their
size, the only fundamental difference in die casting machines is the method
used to inject molten metal into a die. The two methods are hot chamber or cold
chamber. A complete die casting cycle can vary from less than one second for
small components weighing less than an ounce, to two-to-three minutes for a
casting of several pounds, making die casting the fastest technique available
for producing precise non-ferrous metal parts.
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Die casting vs. plastic molding - Die casting produces stronger parts with
closer tolerances that have greater stability and durability. Die cast parts
have greater resistance to temperature extremes and superior electrical
properties.
Die casting vs. sand casting - Die casting produces parts with thinner
walls, closer dimensional limits and smoother surfaces. Production is faster
and labor costs per casting are lower. Finishing costs are also less.
Die casting vs. permanent mold - Die casting offers the same advantages
versus permanent molding as it does compared with sand casting.
Die casting vs. forging - Die casting produces more complex shapes with
closer tolerances, thinner walls and lower finishing costs. Cast coring holes
are not available with forging.
Die casting vs. stamping - Die casting produces complex shapes with
variations possible in section thickness. One casting may replace several
stampings, resulting in reduced assembly time.
Die casting vs. screw machine products - Die casting produces shapes that
are difficult or impossible from bar or tubular stock, while maintaining
tolerances without tooling adjustments. Die casting requires fewer operations
and reduces waste and scrap.
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