die casting metal casting process

Die casting is a metal casting process characterized by the use of a mold cavity to apply high pressure to molten metal. Molds are usually machined from stronger alloys, a process somewhat similar to injection molding. Most die castings are iron-free, such as zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys and their alloys. Depending on the type of die casting, a cold chamber die casting machine or a hot chamber die casting machine is required.

Casting equipment and molds are expensive, so the die-casting process is generally only used for mass-produced products. Manufacturing die-cast components is relatively easy, generally requiring only four major steps, with very low incremental cost per item. Die casting is especially suitable for the manufacture of a large number of small and medium-sized castings, so die casting is the most widely used of various casting processes. Compared with other casting techniques, die casting has a flatter surface and higher dimensional consistency.

Based on the traditional die-casting process, several improved processes have been born, including a non-porous die-casting process that reduces casting defects and eliminates pores. Mainly used for processing zinc, it can reduce waste and increase the yield of direct injection process. There are also new die-casting processes such as precision high-speed die-casting technology and semi-solid die-casting invented by General Dynamics.