What is Die Casting?

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Advantages, applications, and processes. 

A quick introduction 

Die casting is a manufacturing process where sharply defined metal parts are produced by injecting mould cavities with hot, liquid metal which is then cooled to form the desired shape. The moulds used in this process, typically made of steel, are referred to as ‘dies’ – giving the process its name.

What metals are used in die casting?

The most common metals used for die casting are aluminium, magnesium and zinc. Referred to as ‘light alloys’, these materials benefit from properties including excellent electrical and thermal conductivity, mechanical strength, and corrosion resistance. They also enable manufacturers to reduce the weight of parts produced.

What are the most common applications for die cast parts? 

Die casting delivers detail. Every time. Which means it is highly suited to manufacturing parts to tight tolerances, where complexity and consistency are critical. Industries that rely heavily on die casting therefore include automotive, aerospace, telecommunications, and electronics. 
 

The 3 main advantages of die casting are:

 

Lighter parts

Lighter often means leaner (and greener), especially in automotive where part weight directly impacts on things like fuel consumption. 

High dimensional accuracy

The production of thin-wall parts and intricate components with exacting precision standards is perfectly suited to die casting. 

Efficient repeatability

Re-usable metal dies and the accuracy achievable makes die casting ideal for large volume production where consistency and process efficiency are vital. 

 

What specific die casting process is right for me?

There are three main methods for die casting, each with its own benefits and considerations. You can find out more about these, here:

hpdccircleHIGH PRESSURE DIE CASTING

Where molten metal is injected at high speed and high pressure into the die. 

Best for: producing large light alloy parts, in high volumes, at great speed.

gdccircleGRAVITY DIE CASTING

Where molten metal is poured directly from a ladle into a die.

Best for: dense castings with strong mechanical attributes. 

lpdccircleLOW PRESSURE DIE CASTING

Where the die is filled from below with molten metal from a pressurised furnace. 

Best for: controlled die filling for smaller, intricate parts.

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