Die Casting (Process Level 1)

Description

THE PROCESS

Most small aluminum, zinc or magnesium components with a complex shape—camera bodies, housings, the chassis of video recorders—are made by DIE CASTING. It is to metals what injection molding is to polymers, and the two compete directly. In the process, molten metal is injected under high pressure into a metal die through a system of sprues and runners. The pressure is maintained until the component is solid, when the die is opened and the component ejected. The dies are precision-machined from heat-resistant steel and are water cooled to increase life.

PROCESS SCHEMATIC


die casting schematic

Pressure die casting

 

SHAPE

Circular prismatic

True

 

 

 

Non-circular prismatic

True

 

 

 

Solid 3-D

True

 

 

 

Hollow 3-D

True

 

 

 

 
PHYSICAL ATTRIBUTES
Mass range
0.01
-
50
kg
Range of section thickness
0.5
-
12
mm
Surface roughness (A=v. smooth)
A
     
Tolerance 0.15 - 0.5 mm
 
ECONOMIC ATTRIBUTES

Relative tooling cost

high

 

 

 

Relative equipment cost

high

 

 

 

Labor intensity

low

 

 

 

Economic batch size (units)

1e4

1e6

 

 

SUPPORTING INFORMATION

Typical uses

Record player and video player chassis, pulleys and drives, motor frames and cases, switch-gear housings, housings for small appliances and power tools, carburetor and distributor housings, housings for gearboxes and clutches.

 
LINKS

Reference

MaterialUniverse

No warranty is given for the accuracy of this data.  Values marked * are estimates.