Where Is Die Casting Used

Die casting is a quick, reliable and cost-effective manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. It is also called pressure die casting. Die casting is an non-expendable technique and widely used in every aspect of our lives. 

Four parts are required during the die casting process: a furnace, metal, die casting machine, and die. Metal (usually 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 and cold chamber machines. Hot chamber machine is used for alloys with low melting temperatures, such as zinc and cold chamber machine is used for alloys with high melting temperatures, such as aluminum. 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. 

Die Casting Applications: 

In modern day, die casting machines are used that ensures consistent quality control. Die casting is most suitable for casting medium sized parts and nonferrous metal parts of intricate shapes. with complex details. Die-casting is the largest casting technique that is used for manufacturing consumer, commercial and industrial products like automobiles, toys, parts of sink faucet, connector housing, gears, etc.

Here are some application cases:

• Medical: Die casting for manufacturing essential medical products such as surgical instruments, hospital equipment, hospital bed gearboxes and peristaltic pump pumps.

  
  

• Vehicle industry: The vehicle manufacturers need die casting technology to produce automotive parts, such as wheels, cylinder blocks, cylinder heads, manifolds, etc.

  
  

• Outdoor lighting: Factories can count on die casting technique for the manufacturing of outdoor lighting products including housings for street and traffic light enclosures, walk light, PED boxes and aluminum light enclosures, bullet light fixtures, coach lights and wall sconce fixtures.

  
  

• Firearms: The firearms industry manufacturers need to use die casting during producing trigger guards, and other shotgun and rifle parts.

  
  

• Industrial equipment: The die casting services encompass the manufacturing of numerous types of industrial equipment such as compressor and piston connecting rods, porter cable pump housings, wall mount bearing housings, industrial pumps, air compressors and many others. 

Why is die casting widely used? It has many advantages as below:

1. High production rate. 

2. High accuracy in part dimensions. 

3. Smooth surface finish for minimum mechanical finishing. 

4. Ability to make many intricate parts such as hole opening slot trademark number etc.

5. Much thinner wall sections can be produced which can’t be produced by other casting methods. 

6. Varieties of alloys can be used as per design requirements. For example zinc can be used for intricate forms and plasticity, aluminum for higher structural strength, rigidity and light weight. 

7. Ability to cast inserts such as pins studs shafts, fasteners etc.