Die casting is a metal casting process that is characterized by forcing
molten metal under high pressure into a mold cavity. The mold cavity is created
using two hardened tool steel dies which have been machined into shape and work
similarly to an injection mold during the process. Most die castings are made
from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead,
pewter and tin based alloys. Depending on the type of metal being cast, a hot-
or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and
this tends to limit the process to high volume production. Manufacture of parts
using die casting is relatively simple, involving only four main steps, which
keeps the incremental cost per item low. It is especially suited for a large
quantity of small to medium-sized castings, which is why die casting produces
more castings than any other casting process.Die castings are characterized
by a very good surface finish (by casting standards) and dimensional
consistency.
Two variants are pore-free die casting, which is used to eliminate gas
porosity defects; and direct injection die casting, which is used with zinc
castings to reduce scrap and increase yield.
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