Die casting component parts, decorative trim, and/or finished products offer many features, advantages and benefits to those who specify this manufacturing process.
Die casting provides complex shapes within closer tolerances than many other mass production processes.
Die castings are produced at high rates of production. Little or no machining is required.
Die castings can be produced with thinner walls than those obtainable by other casting methods … and much stronger than plastic injection moldings with the same dimensions.
Die casting provide parts which are durable, dimensionally stable, and have the feel and appearance of quality.
Die casting dies can produce thousands of identical castings within specified tolerances before additional tooling may be required.
Zinc castingscan be easily plated or finished with a minimum of surface preparation.
Die castings can be produced with surfaces simulating a wide variety of textures.
Die cast surfaces, as cast, are smoother than most other forms of casting.
Holes in die castings can be cored, and made to tap drill sizes.
External threads on parts can be readily die cast.
Die castings provide integral fastening elements, such as bosses and studs, which can result in assembly economies.
Inserts of other metals and some non-metals can be die cast in place.
Corrosion resistance of die casting alloys rates from good to high.
Die castings are monolithic. They combine many functions in one, complex shaped part. Because die castings do not consist of separate parts, welded or fastened together, the strength is that of the material, not that of threads or welds, etc.
Die casting is an efficient, economical process which, when used to its maximum potential, replaces assemblies of a variety of parts produced by various manufacturing processes at significant savings in cost and labor.
COMPARISONS WITH OTHER PRODUCTS
Plastics injection moldings
Compared with plastic injection moldings, die castings are stronger, stiffer, more stable dimensionally, more heat resistant, and are far superior to plastics on a properties/cost basis. They help prevent radio frequency and electromagnetic emissions. For chrome plating, die castings are much superior to plastic. Die castings have a high degree of permanence under load when compared to plastics, are completely resistant to ultra-violet rays, weathering, and stress-cracking in the presence of various reagents. Manufacturing cycles for producing die castings are much faster than for plastic injection moldings. Plastics, however, may be cheaper on a unit volume basis, have color inherent properties which tend to eliminate finishing, are temperature sensitive, and are good electrical insulators.
Compared with sand castings, die castings require much less machining; can be made with thinner walls; can have all or nearly all holes cored to size; can be held within much closer dimensional limits; are produced more rapidly in dies which make thousands of die castings without replacement; do not require new cores for each casting; are easily provided with inserts die cast in place; have smoother surfaces and involve much less labor cost per casting. Sand castings, on the other hand, can be made from ferrous metals and from many non-ferrous alloys not suitable for die casting. Shapes not producible by die casting are available in sand castings; maximum size can be greater; tooling cost is often less and small quantities can be produced more economically.
Permanent mold castings
Compared with permanent mold castings, die castings can be made to closer dimensional limits and with thinner sections; holes can be cored; are produced at higher rates with less manual labor; have smoother surfaces and usually cost less per die casting. Permanent mold casting involves somewhat lower tooling costs; can be made with sand cores yielding shapes not available in die casting.
Compared with forgings, die castings can be made more complex in shape and have shapes not forgeable; can have thinner sections; be held to closer dimensions and have coring not feasible in forgings. Forgings, however, are denser and stronger than die castings; have properties of wrought alloys; can be produced in ferrous and other metals and in sizes not suitable for die castings.
Compared with stampings, one die casting can often replace several parts. Die castings frequently require fewer assembly operations; can be held within closer dimensional limits; can have almost any desired variation in section thickness; involve less waste in scrap; are producible in more complex shapes and can be made in shapes not producible in stamped forms. Stampings, on the other hand, have properties of wrought metals; can be made in steel and in alloys not suitable for die casting; in their simpler forms, are produced more rapidly; and may weigh less than die castings.
Screw machine products
Compared with screw machine products, die castings are often produced more rapidly; involve much less waste in scrap; can be made in shapes difficult or impossible to produce from bar or tubular stock; and may require fewer operations. On the other hand, screw machine products can be made from steel and alloys which cannot be die cast; they have the properties of wrought metals; and they require less tooling expense.
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