Die Casting

Die Casting

What is Die Casting?

Die Casting is a manufacturing process in which hot, molten metal is forced through injection and under pressure into an aluminum mold, or “die” to form a shape or part.  Die casting is used in many markets, including engines, hardware, appliances, tools, and it is used abundantly to manufacture auto power train parts.  Because die casting uses a custom mold, there is a wide variety of parts or products that may be manufactured this way.  You may also mass produce your die cast part easily when the die cast process. 

The Die Casting Process

Cold Chamber Die Cast

There are two methods of die casting.  One method uses a cold-chamber die cast machine.  When using a metal with a high melting point, cold chamber die casting is the best way to go.  Metals that have a high melting point include aluminum and zinc.  Molten metal is moved from a separate furnace, where it is heated.  After it is transported to the cold-chamber machine, it is fed into an injection cylinder (which is unheated).  A hydraulic piston then shoots the metal into the die.  This is a slower process simply because the metal is heated in a different place and must be transported from the furnace to the cold-chamber die cast machine.

Hot Chamber Die Cast

The other die casting process uses a hot-chamber die cast machine (or gooseneck machines) and is a faster process because the molten metal is melted there in the machine.   Hot chamber die cast machines are used for metals such as zinc, copper and magnesium, lead based alloys, and any other metals that have a low melting point.  These machines are called gooseneck machines because the furnace is attached to it with a gooseneck metal feed system.  The hydraulic powered piston forces the metal into the die. 

The die casting process is often used over other manufacturing processes for several reasons.  Die casting can produce strong part with tight tolerances.  As mentioned before, die casting can produce products with more complex shapes.  Often, the finishing costs of die casting vs other manufacturing processes, such as forging or sand casting, is less.