Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die casting machine. The differences between these machines will be detailed in the sections on equipment and tooling. However, in both machines, after the molten metal is injected into the dies, it rapidly cools and solidifies into the final part.
The castings that are created in this process can vary greatly in size and weight, ranging from a couple ounces to 100 pounds. One common application of die cast parts are housings - thin-walled enclosures, often requiring many ribs and bosses on the interior. Metal housings for a variety of appliances and equipment are often die cast. Several automobile components are also manufactured using die casting, including pistons, cylinder heads, and engine blocks. Other common die cast parts include propellers, gears, bushings, pumps, valves hardware, and light industy.
| Typical | Feasible | |
| Shapes: | Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex |
Flat Thin-walled: Cylindrical Thin-walled: Cubic |
|---|---|---|
| Part size: | Weight: 0.5 oz - 500 lb | |
| Materials: |
Metals Tin |
Copper and Required |
| Surface finish - Ra: | 32 - 63 μin | 16 - 125 μin |
| Tolerance: | ± 0.015 in. | ± 0.0005 in. |
| Max wall thickness: | 0.05 - 0.5 in. | 0.015 - 1.5 in. |
| Quantity: | 10000 - 1000000 Pcs | 1000 - 1000000 Pcs |
| Lead time: | Months | Weeks |
| Advantages: | Can produce large parts Can form complex shapes High strength parts Very good surface finish and accuracy High production rate Low labor cost Scrap can be recycled |
|
| Disadvantages: | Trimming is required High tooling and equipment cost Limited die life Long lead time |
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| Applications: | Automotive Components, Engine components, pump and valve components, Cover, appliance housing, hardware and light industry. | |