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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. There are two main types of die casting machines - hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum). 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, called the casting. The steps in this process are described in greater detail in the next section.
Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Parts have long service life and may be designed to complement the visual appeal of the surrounding part. Designers can gain a number of advantages and benefits by specifying die cast parts.
High-speed production – Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.
Dimensional accuracy and stability – Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant.
Strength and weight – Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
Multiple finishing techniques – Die cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.
Simplified Assembly – Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.
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