Die casting is a widely used permanent mould metal casting process, in which molten metal is forced into the mould called “Dies” at pressures ranging from 0.7 to 700 MPa, where it solidifies into a metal cast. Die castings, sometimes known as pressure die casting, are used in automotive housings, appliance components, and toys.
Nonferrous metals aluminium, zinc, copper, magnesium, lead, pewter, and tin-based alloys, are widely used to produce robust, high-quality complex components. Different chemical elements are added to the molten metal to achieve the desired metal chemical composition to satisfy some challenging parts.
Depending on the part’s complexity, size and material, the final piece is either single or multiple casts. Dies can have either a single cavity, multiple cavities, several different part cavities, or a unit die in which multiple dies are combined to make a master holding die.
The process was introduced in the mid-19th century to make parts for the printing industry. Since then, it has emerged as one of the most critical manufacturing processes with many technological advancements, such as metallurgical control measures to improve the manufacturing criteria.
As shown below, die casting can produce parts with complex features and an excellent surface finish. It can also compete with other manufacturing techniques such as sheet metal stamping, forging, and other casting processes.
Read more: What is Die Casting?