At USD 24.91
billion in 2018, the worldwide aluminum die-casting market was valued. From
2019 to 2025, the industry is expected to grow at a compound annual rate of
10.1%.
It is
because die casting is becoming one of the most dependent production
technologies that this growth rate has occurred. Die casting is used to make a
wide variety of goods in almost every industry and business niche imaginable.
However,
die-cast goods are only as excellent as the metals they're made from, just like
any other metal fabrication method. Overall product quality, durability, and
aesthetics are all impacted by the metals used in the manufacturing process.
Thus, this article will focus on the different metals used in die casting.
As a prelude
to discussing the best metals for die casting, let's take a closer look at the
procedure.
Die
Casting is a process.
Die casting
is a metal production technique using high pressure and reusable metal dies.
Using die casting, metal pieces may be produced that are precisely sized, well
defined, and either smooth or textured on the surface.
The
Die Casting Process in Detail
Simple,
quick, and stable die casting is standard metal manufacturing. The following is
a step-by-step guide to die casting:
·
The mold
must be divided into two or more portions to remove castings from a steel mold.
·
Using this
mold, you may make hundreds of castings in a short period.
The parts
are positioned in a stationary configuration after being inserted into the
machine (fixed die half). Both sections may be moved simultaneously (injector
die half). The machine begins the casting process by clamping the two parts
together.
·
Injecting
molten metal into the die cavity causes the metal to solidify very quickly.
·
The casting
is expelled when the die halves are separated.
·
It is
possible to create a die that is simple or complicated depending on the
intricacy of the casting.
Die
casting is a two-step process.
Die Casting in a Hot Chamber
Pressure is
used to drive hot metal into a pre-formed mold in hot chamber die casting, much
as in other types of casting. However, in this procedure, the metal is heated
in the casting machine itself, rather than in a separate furnace, rather than
in an individual furnace.
·
Aluminum
The following
metals may be cast in a hot chamber:
·
Zinc
·
Alloys of
magnesium
Melting
points of many other metals
Alloys that
do not corrode metal pots, cylinders, or plungers may be processed in hot
chamber machines.
Die
Casting in a Cold Chamber
Despite its
name, cold chamber dies casting does not need hard metals. Heating metal in a
furnace separate from the casting machine and then pouring the molten metal
into the machine.
·
Metals with
high melting points benefit from a cold chamber machine (e.g., aluminum).
·
The metal is
first melted, and then poured into a cool chamber to solidify.
·
A
hydraulically-powered plunger pushes the metal into the die in the cold
chamber.
·
Comparing
Die Casting with Sand Casting Techniques
Sand
casting, like die casting, is a metal production technique that uses molten
metal to fill a mold with sand. Each process is unique in its way, even if they
all aim to achieve the same objective.
Since high
pressure is used, die casting is the fastest method for producing precision
non-ferrous metal components. It's done when the metal cools and hardens after
being withdrawn from the mold. Afterward, the mold is re-opened and ready for
the next pour.
A new mold
must be made for each casting, and no high pressure is used in sand casting. It
might take hours or even days to build a new mold, depending on the intricacy
of the mold. Even though a sand mold is less expensive and takes less equipment
to make, this procedure is best suited for casting a smaller number of pieces.
For
Die Casting, Which Metals Are the Most Popular?
The metals
and alloys utilized in a die casting project range from stainless steel to
aluminum alloys. There are advantages and disadvantages to each alloy,
depending on the application.
A
professional metal fabrication firm can help you comprehend all of the
mechanical and physical qualities and the compositions of various alloys.
Die-cast metals include the following:
·
Zinc
·
Aluminum
·
Magnesium
·
Brass,
copper, lead, and tin is also utilized in bespoke die casting tasks but is more
often employed in larger production runs.
Alloys,
mixtures of several elements, may be found in metal die-cast components, but
selecting the right one requires careful study. Because each alloy has its
unique features, benefits, and drawbacks, it's essential to plan when selecting
an alloy.
Die-casting
of aluminum
When it
comes to dying casting, aluminum is one of the most often utilized metals.
Because aluminum is a relatively light metal, aluminum may make light and
intense pieces. In addition, it can sustain greater working temperatures and
has a broader range of finishing possibilities for aluminum components.
Aluminum and
aluminum-zinc alloys, despite their higher cost, are excellent solutions for
industrial applications. Their corrosion-resistant properties lead to longer
life and more excellent safety. It's also unmatched in its strength, hardness,
and weight ratios.
In addition
to being simple to cast, aluminum has another significant advantage: it's
lightweight. An excellent conductor of both heat and electricity, it is ideal.
As a result, aluminum is a fantastic choice for manufacturing components in
computers, energy management, and other high-tech areas.
Aluminum is
widely used in manufacturing industrial components, vehicle parts, technology
items, aerospace products, and much more because of its numerous advantages.
Dies
made out of Zinc
Zinc is a
widely utilized metal in die casting in addition to aluminum. In addition, the
automotive and medical supply sectors often employ Zinc to cast items.
Zinc
castings are a good option for customizing products for aesthetic reasons.
Plated or painted, as required, the material may be used. It's also easy to
work on since it has a smooth surface. As a result of Zinc's ability to make
components with both specific visual quality and limited form morphological
tolerances,
As a result
of its low melting point, Zinc takes less energy to be produced than other
metals. Die casting's low melting point also extends the life of the mold, which
is another essential element in its relevance to medical devices.
Finally,
Zinc's exceptional levels of corrosion resistance and increased heat
conductivity make it an excellent choice. As a result, this substance is
long-lasting, solid, and stable.
Die
Casting of Magnesium
Magnesium is
a popular metal used in die casting, as is aluminum. Magnesium is the best in
terms of machinability, strength-to-weight ratio, and die casting weight.
There are
several advantages to using Magnesium alloys over other cast metals, such as
improved fluidity, decreased susceptibility to hydrogen porosity, and more
extraordinary casting ability. In addition, as an EMI and RFI shielding
material, magnesium is ideal for electrical connections and housings.
Magnesium may
be found in a wide variety of products. For example, magnesium is often
utilized to produce magnesium-based components like connections and housings to
safeguard medical and laboratory equipment from interfering signals.
Furthermore,
magnesium is 75% lighter than steel while retaining the same level of strength.
As a result, it is a superior choice for casting thin-walled, intricate
net-shaped parts. In addition, the dimensional stability is improved.
·
It is
feasible to attain tighter tolerances with magnesium castings than with steel.
·
Corrosion
may be seen on the surface of die-cast metal.
Because iron
is present, all ferrous metals, including carbon steel, alloy steel, and
stainless steel, are susceptible to rusting. Therefore, die casting these
metals is conceivable, although it is not very frequent because of their
propensity to rust.
Aluminum and
copper, both non-ferrous metals, contain only minute quantities of iron. As a
result, rust is not an issue. However, they are susceptible to corrosion, which
is determined mainly by the working conditions in which they are used.
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