Die casting is a manufacturing method used to make a range of metal products, from complex automobile components to simple paper clips. The basic process involves injecting the molten metal into mold cavities where they harden to produce the desired shape.
This method minimizes the requirement for post-production machining and is used to produce metallic parts in bulk. Die casting is the preferred way of producing bulk metal parts in power tools, aerospace, and auto industries.
Die casting in China
Increasing demand from various industries, including the automotive industry and manufacturing sector in the Asia-Pacific region, has led to the creation of die casting hubs, particularly in China.
The push for die casting is also due to the “Made in China” strategy adopted by China that is focused on boosting manufacturing in various sectors.
The prime advantage of choosing China for die casting is the low manufacturing costs and cheaper labor. In recent times, private manufacturers in China have continued to become more and more professional and competitive in making die-cast components. Regional manufacturers in some countries, including China, account for 55% of the global die casting market.
China has been a leader in metal die-casting and accounts for 45% of the world’s casting production. The volume of die castings made in China foundries reached 3.7 million tons in 2015. The die casting industry in China has registered a 13% annual growth rate in the last two decades.
A majority of die castings made in China are used for motorcycles and automobiles.
Advantages of die casting
High-quality products can be produced in this method that has a long service life.Die casting produces bulk metal parts that retain their uniformity.The production process is quick and seamless as minimal maintenance is required for die casting tools.Any surface texture, geometry, size, and luster can be created using die casting.Wide-ranging assembly features, including drill holes, bosses, and studs, can be integrated into the design of the mold, which minimizes post-production assembly.High accuracy.Designs of varying complexities or details are repeatable.Reduced cost as there is only one process of production.Minimal scrap and waste material.Die casting metals
There are many types of metals and alloys used in die casting, and the choice of a particular material depends on the weight, budget, and properties of the material. The most commonly used metals in die casting are non-ferrous metals, which are metals that do not contain a large amount of iron and are known for their malleability. Some examples of non-ferrous metals are copper, zinc, tin, aluminum, nickel, and titanium.
Out of these, the most commonly used non-ferrous metal is aluminum that has a share of as much as 80 percent of die casting. The other preferred non-ferrous metals are magnesium, zinc, copper, tin, and lead. These metals have specific properties that make each of them the ideal choice for a specific application. For instance, metals such as magnesium and aluminum have high melting points, while lead and zinc have low melting points. Other than melting points, each metal offers distinct advantages:
Zinc is a preferred metal for die casting, given its high impact strength and ductility. Besides, zinc is easy to plate and economical when die casting small parts and prolongs die life.Magnesium is one of the easiest metals to machine while being the lightest alloy and has an excellent ratio of strength-to-weight ratio.Aluminum is a popular die casting metal as it has good corrosion resistance and is lightweight apart from having high dimensional stability to hold complex shapes. The other advantages of aluminum as a die casting metal are its strong mechanical properties, high electrical and thermal conductivity, and ability to retain strength even at high temperatures.Copper has the highest mechanical properties and is preferred for its high corrosion resistance, hardness, and excellent wear resistance. Like aluminum, copper also has excellent dimensional stability while its strength is very close to steel parts.Tin and lead have high density and are preferred for their special corrosion resistance properties. These metals offer optimal dimensional accuracy. However, lead is a heavy metal that is linked to health concerns. This is the reason why it is not used to make components for food-service applications. Another alloy of tin, lead, and antimony finds application in letterpress printing as well as hot foil blocking.Silicon tombac is an alloy made of zinc, silicon, and copper that gives it high strength and is typically used as an alternative for cast steel parts.
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