Die casting is slowly emerging as one of the most essential manufacturing techniques in most industries. Well, this comes as no surprise as the tooling technique comes with plenty of benefits as well as have a first turn-around time ensuring your products hit the market faster giving you an edge over your competitors.
The process entails a metal casting process utilizes the mold cavity plus high pressure to create the part/product. The molds are usually produced from alloys which have high strength just as injection molding.
Die casting process mainly uses non-ferrous metals such as lead, tin, aluminum, magnesium, zinc, copper as well as other alloys.
Benefits and disadvantages of the die-casting process
Die casting is used in a wide variety of industrial sectors such as medical, household, lighting, industrial, and automotive. Some of the advantages and disadvantages that you can expect from the die casting process include:
Benefits of die casting
Smooth surfaces and high precision
Die casting process has high precision as well as high tolerance due to excellent surface finishing as well as high dimensional accuracy producing machined parts of high quality with top-class finishing.
The end-product can be delivered to the market directly as it doesn’t require finishing or machining services which boosts the utilization of the alloys ensuring there is less material wastage saving on machining cost as well as the overall production process.
Excellent mechanical properties
The molten metal usually cools off at a faster rate enabling it to crystallize under immense pressure, the crystalline grains at the top of the casting are usually fine and compact which play a crucial role as it contributes to the hardness and strength of the product.
Produces thin-walled and complex parts
The die casting process is synonymous with complex geometries and thin walls. The walls produced from die casting is usually thinner than the ones produced by sand and metal mold castings.
Die casting is among the few manufacturing techniques that allow the integration of fasteners and complex inserts into the final product. This goes a long way in saving on the materials used and cost.
It also allows the manufacturing of complex and delicate parts; it also ensures the functionality is improved.
Allows for mass production
Die casting allows for the production of durable and structurally stable die-cast parts, thus there is no need for machining.
Provides varying surface textures
The parts/products manufactured from the die casting process has a wide range of techniques and finishing services. The manufacturing ensures your machined parts have smooth surfaces that are textured.
Cons of die casting
The porosity which results from the die casting process makes it quite hard when it comes to curing or heat treatment.
The upfront cost incurred by both the manufacturer and client as its expensive to make the mold. But this cost can be offset with high volume production
Shorter life cycle
Die casting normally requires a high melting point on the alloy and at some point, it can result in thermal fatigue exerted on the mold which shortens its life cycle.