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Introduction
This article contains information regarding die casting and its use.
Here is what you will learn:
What is die casting?
The types of metal used in die casting
Processes and how die castings are produced
Die casting: hot and cold
Die casting design geometry
And much more.
Chapter One – What is Die Casting?
Die casting is a high pressure metal casting process that forces molten metal into a mold. It produces dimensionally accurate precision metal parts with a high quality finish. Its ability to produce detailed parts makes it perfect for the mass production of products. Die castings are made from non-ferrous metals such as zinc, copper, aluminum, magnesium, lead, pewter, and tin.
The two methods of die casting are hot or cold chambers. The process that is used depends on the type of metal and the part. The cold chamber method is used with metals that have a high melting point such as alloys of aluminum, brass, or copper. Hot chamber die casting is limited to metals that won’t dissolve when heated such as zinc, lead, and magnesium alloys.
The process of die casting is efficient, economical that offers a broad range of shapes and components. Parts produced have a long life and can be produced to be visually appealing giving designers significant advantages and benefits.
The high speed of die casting produces complex shapes with close tolerances requiring no after production processing. There is no need for additional tooling or shaping. Final parts are heat resistant with high tensile strength.
Depending on the feature and its size, tolerances of +/-.002" can be held in aluminum with tolerances of +/-.0005" in zinc.
What Is the Difference Between Die Casting and Forging?
Die casting and forging are two distinct metal forming processes with notable differences.
Die casting involves forcing molten metal into a mold cavity at high pressure, resulting in intricate and detailed shapes with excellent dimensional accuracy. This process is ideal for producing complex, thin-walled parts with a smooth surface finish, making it suitable for applications like automotive components and consumer electronics.
Forging involves shaping metal by applying compressive forces through hammering or pressing at high temperatures. This method enhances the material's strength and grain structure, yielding robust and durable parts often used in heavy machinery, aerospace, and construction equipment. While die casting offers precision and complexity, forging excels in strength and structural integrity.
Chapter Two – Types of Metals Used in Die Casting
The type of metal used in die cast depends on its final use. Aluminum is used for automobile and truck parts because of its light weight and corrosion resistance, while medical instruments are made from stainless steel.
Metals for casting must be able to maintain their properties and characteristics during and after the melting process. The types are:
More information on each of the metal types is below.
The advantages and disadvantages of zinc, bronze, and aluminum
Zinc
Advantages
Zinc is one of the best and often overlooked die casting alloys since it does most everything very well. It weighs 2.3 times more than aluminum, which means that aluminum is used in place of zinc for larger die castings based on weight and material costs.
Zinc is the easiest metal to cast. It has high ductility, impact strength, and can easily be plated. The strength of zinc comes from its alloyed metals. Parts cast from zinc have very close tolerances. Zinc alloyed parts have higher impact resistance than cast aluminum, plastics, and grey cast iron.
Exceptional casting fluidity with ZAMAC alloys provides for thin-wall castability with thicknesses of .025 inches or .65mm, resulting in smaller, lighter, low cost components.
The low casting temperature of zinc results in minimal thermal shock, which extends the life of die casting tools more than 10 times that of aluminum dies.
Zinc alloys are rigid with an elastic moduli greater than aluminum and magnesium alloys as well as engineering plastics. This, combined with their strength, reduces the volume of casting, which saves space and weight.
Bushing and wear inserts in component designs can be eliminated due to zinc's bearing properties, outperforming bronze in heavy- duty industrial applications.
Disadvantages
Zinc has a relatively low melting point, approximately 419°C (786°F), compared to other metals used in die casting, such as aluminum and magnesium. This limitation can restrict the use of zinc die casting in high-temperature applications.
While zinc die castings can achieve good surface finishes, they may not be as corrosion-resistant as other materials like aluminum or stainless steel. Proper post-processing and coatings may be required to enhance corrosion resistance.
Aluminum
Advantages
Aluminum is a lightweight material, making it ideal for applications where weight reduction is important, such as in the automotive and aerospace industries. Its low density helps improve fuel efficiency and performance.
Despite its lightweight nature, aluminum offers a high strength-to-weight ratio. It provides good structural integrity while keeping the overall weight of the component low.
Aluminum has excellent thermal conductivity, which makes it suitable for applications where heat dissipation is crucial, such as in electronic enclosures and heat sinks.
Disadvantages
Aluminum has a relatively high shrinkage rate when it cools after being cast. This can lead to dimensional inaccuracies in the finished parts, which may require additional machining or post-processing to meet tight tolerance requirements.
Aluminum alloys can be more brittle than other materials like zinc or magnesium. This brittleness can lead to issues such as cracking or breakage under heavy loads or impact, making aluminum die castings less suitable for applications requiring high durability.
Brass
Advantages
Brass is naturally corrosion-resistant, making it a preferred choice for components that may be exposed to moisture or harsh environmental conditions. It resists rust and tarnish, which can extend the lifespan of the die-cast parts.
Brass also has high thermal conductivity, which can be an advantage for components that need to dissipate heat efficiently. This is especially valuable in electrical and electronic applications.
Disadvantages
Melting of brass can be a complex and an involved process. Die casting has to be constantly monitored and labor intensive. Improperly inserted lubricants can burn the casting. Scaling is common as well as porosity (small voids or holes) and die defects.
Brass has a lower melting point compared to some other die-casting materials, which can limit its suitability for high-temperature applications. This can result in parts deforming or failing under extreme heat.
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Chapter Three – Die Casting – Hot and Cold
The most common types of die casting are hot and cold. The difference between them is that hot chamber die casting heats metals in the casting machine while cold chamber heats metal in a furnace and transfers the molten metal to the casting machine. The process produces complex shapes with close tolerances, heat resistance, and high tensile strength with little need for additional tooling and shaping.
Hot chamber
Hot chamber die casting uses alloys with a low melting temperature. Dies have two sections – movable and fixed. The fixed half is the covered die and is mounted on a stationary platen aligned with the gooseneck that connects to the chamber for inserting the molten metal. The movable die is the ejector die.
Molten metal is held in an open holding pot that is connected to the combustion area or furnace from which the molten metal enters the holding pot. With the plunger, that drives the molten metal up the gooseneck into the mold, in the up position the molten metal flows into the shot chamber. Once the metal is present, the plunger moves down forcing the molten metal up the gooseneck into the die.
The two halves of the mold are forced together under great pressure to close the mold. The plunger remains down until the molten metal in the die cools. After solidification, an ejection system pushes the casting out from the two die halves.
Cold chamber
Cold chamber refers to the temperature of the chamber when the molten metal is introduced. With hot chamber casting, the chamber is filled with molten metal prior to beginning the casting process. In the cold chamber process, the chamber is at room temperature before the molten metal is poured.
High melting temperature metal alloys are used for cold chambered die casting. The molten metal is heated in a separate furnace and ladled or poured through a pouring hole into the shot chamber that encloses a ram for pushing the molten metal into the die. The parts of the die are the same with movable and fixed sections. The cold chambered method forces the molten metal in vertically.
As the ram moves vertically toward the die, the molten metal is forced forward at pressures between 2000 psi or 2 ksi to 20,000 psi or 20 ksi. The pressure is held by the ram until the molten metal cools and solidifies to be ejected.
Die Casting Steps
The basic steps for high pressure die casting are listed below. They vary depending on the chosen process of a manufacturer. (from https://www.thediecasting.com/the-die-casting-process-step-by-step/)
Step one – Preparation of the Die: To prepare the die for casting, it is sprayed with a lubricant or releasing agent. Lubricants allow for clean part release by placing a film over the part. To make application easy, the lubricating agent is mixed with water that evaporates when sprayed on the heated steel die.
Step two – Clamping the Die: The halves of the die are clamped together under high pressure. The amount of force is determined by the machine.
Step three – Cooling: Cooling time depends on the type of metal and the temperature at which it will solidify. The geometry and wall thickness of the part are also factors.
Step four – Ejection: The halves of the mold are separated, and an ejection mechanism forces the part out of the die. The amount of force for removal has to be carefully monitored.
Step five – Trimming: Flashing (a thin portion of metal around the edge of a casting) is removed, known as deflashing, which is excess material such as metal that may have seeped between the die halves or runners.
Die Casting Terms
(from www.kineticdiecasting.com)
Trim Die - Cuts off excess
Slides - Accommodate undercuts
Interchangeable cores - Makes different size holes
Waterlines - Increases production cycles by cooling part
Vents - Allows gasses to escape
Overflows - Regulates the temperature
Ejector Pins - Pushes the die cast part out of the mold.
Draft – Is perpendicular to parting plane and allows the part to eject.
Parting line – Where the two halves of die meet.
Chapter Four – Die Casting Design Geometry
Die casting design geometry determines how parts fill and cool as well as how their geometry affects stress, grain, and porosity. The grain structure and level of stress are determined by the type of metal.
The examples in the above diagram are a sampling of the types of geometric features produced by die casting.
Essentials of geometry planning
Geometry prevents
Poor fluid life
Part shrinkage
Problems with solidification
Hot cracking
Post casting checks
Finishing
Geometric features
Draft
Drafting is a draft angle that varies depending on the type of wall and surface, the depth of the surface, and the selected metal. A mathematical formula determines the angle.
Fillet radii
Fillet radii makes a part stronger by redirecting stress concentration at sharp interior corners by distributing it over the broader volume of the fillet to lessen weak points. It prevents cracking during straightening.
Parting line
Parting line is where the two halves of the die meet, defines the inside and outside surfaces, and which side of the die is the cover and which is the ejector.
Bosses
Bosses are mounting points, stand offs, and are designed to maintain uniform wall thicknesses to eliminate after casting machining.
Ribs
Ribs help the molten metal fill all parts of the die casting. They provide a path for molten metal and simplify and speed up ejection.
Holes and windows
Holes and windows require the highest amount of drafting since they form a connection with the surface of the die making the ejection difficult and may block the flow of the molten metal.
Holes can be seen in this die cast plunger lock from Window Repair Parts.
Chapter Five – Variations of Die Casting
There are several variations of die casting, each with its own unique characteristics and advantages. These variations are chosen based on factors such as material selection, part geometry, production volume, and quality requirements. Manufacturers carefully consider these factors when deciding which die casting method to use for a specific application.
The variations described below have been developed to overcome flaws, errors, deformities, and other issues found in die casting operations.
Variants
Pore free
Prior to injecting or pouring the molten metal, the die cavity is filled with oxygen. When the hot metal enters the cavity, the oxygen chemically combines with it to prevent gas bubbles eliminating trapped gas pores. In the diagram below, note the opening for active gas in this cold forging process.
Acurad
Acurad is an anagram for accurate, reliable, and dense. It combines stable fill and directional solidification to create fast cycle times. It includes thermal analysis, flow and fill modeling, heat treatable castings, and indirect squeezing. Double pistons increase the pressure when the shot is partially solidified.
Gravity
Molten metal is poured directly into a permanent die completely filling, which turbulence, oxidation, and foaming. The die can be vertical, horizontal, or tilted. Parts have high quality, strength, mechanical characteristics, and stiffness.
Investment
Investment or lost wax casting, is labor intensive process involving shaping of the mold from a wax prototype dipped in liquid ceramic. When the ceramic hardens, the wax is melted away. Molten metal is poured into the ceramic cavity. After solidification, the ceramic mold is broken away and the metal casting removed.
Vacuum assisted high pressure
The die is placed in an airtight housing. Pressure is created in the die cavity drawing in the molten metal where it solidifies and is ejected.
Semi-Solid
Semi-Solid metal in a semi-solid, or slurry type condition, is swirled, poured, and sent into a shot sleeve to be forced, under pressure, into the mold cavity. Parts have excellent surface finishes, close dimensional tolerances, and good microstructure.
Low Pressure
Low Pressure the chamber with the molten metal is below the die, as can be seen in the diagram. It is pushed up through an intake port into the die chamber. The pressure is maintained until the molten metal solidifies.
Chapter Six – Die Casting Dies
Die castings are made from steel alloys and have two sections – fixed or cover half and the ejector or removable half. A sprue hole, a round, tapered hole, allows the molten metal to enter the die cavity. The ejection half has a runner or passageway and gate or inlet to route the heated metal in the die cavity. The two halves are locked together with ejector pins.
The die has an opening for a coolant or lubricant, which helps in releasing the part from and keeping the temperature even. Lubricant improves the finish and prevents the part from sticking to the die cavity. The most common form of lubricant is water mixed with oil.
A die can last through several thousand parts, which depends on the amount of stress it endure, maintains, and cared. Die casting dies are expensive and can add to the cost of the final part.
Types of dies
There are several types of dies that have been developed. Due to the nature of die casting, dies are ever changing and being introduced.
Below is a description of a few of the common ones.
Single cavity
Produces a single unit and is used with machines that handle one die due to shot height, locking force, and die size. There are useful for low production runs, center gating (the entrance for the molten metal), and complex parts with multidirectional features.
Multiple cavity
Multiple cavity dies are capable of producing multiples of the same part during one casting and are specially designed.
Combination
Combination is a form of a multiple cavity die. Instead of casting similar parts, combination dies produce different parts that fit together. The images of the parts in the diagram are examples of ones that could be produced form on die casting.
Unit
Unit dies are able to be inserted into larger dies. The larger die is fixed while the unit die can be varied to make different components. There are limitations regarding the size and weight of a unit die and whether it can be inserted.
Chapter Seven – Advantages and Disadvantages of Die Casting
Die casting is the quickest and most economical of production processes. Hundreds of thousands of parts can be produced from one mold producing dimensionally accurate and precision parts. Listed below are the advantages and disadvantages of die casting.
Advantages
Excellent dimensional Accuracy
Dimensional accuracy is typically 0.1 mm for the first 2.5 cm and 0.02 mm for each additional centimeter. (from https://firstratemold.com/advantages-and-disadvantages-of-die-casting/)
Smooth Surfaces
Surface finishes of 1 – 25 μm. (from website https://firstratemold.com/advantages-and-disadvantages-of-die-casting/).
Production Rate
The production rate is dependent on cavitation, the number of cavities in a mold. One mold can complete 200 to 300 shots per hour. With smaller parts, it can increase to the thousands.
Detailed Parts
Reproduces any design down to the finest details with thin walls and structures.
Inserts
Threaded inserts, bearings, and addons can be easily included.
Tensile strength
Parts have tensile strengths of 60,000 psi or a 415 MPa.
Automation
Hydraulic and pneumatic equipment are commonly used for efficiency and lower cost.
Tolerances
Produces complex parts with extremely close tolerances.
Disadvantages
Cost
Every mold has to be individually precision manufactured, which requires hours of crafting, shaping, and forming.
Furnaces
Furnaces have to burn into the 1000‘s of degrees consuming costly energy that produces pollutants that have to be air filter controlled.
Equipment
Molding and shaping equipment is precision designed to withstand the stress of the heating process.
Metals
Only metals with high fluidity can be used, which influences the types of parts to be produced.
Labor intensive
The process has to be closely monitored and managed especially during the cooling phase.
Dies
Dies are made of hardened steel and cannot be adjusted or changed. They are very expensive and costly.
Defects
Porosity, shrinkage, and metal pouring are common defects.
Production time
Requires very long lead times.
Conclusion
The die casting process is a central part in the production and manufacture of most of the products we use.
Society is dependent on die casting and its ability to produce technical devices with high precision.
It is very likely that any new innovations will rely on die casting to produce major components economically and efficiently.
This short synopsis has provided a brief overview of die casting, its processes, and how it can be implemented and used.
In response to what you have read, add your comments below for more information or guidance on how to contact die casting manufacturers.
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