Die casting is a process that is used in making engineering metal parts. This is done by forcing molten metal under high pressure to steel molds that can be reused. The molds used are called dies and they can be designed to make complex shapes with high accuracy.
Plastics Injection Moldings
Die-castings are stronger and more stable when compared to plastic injection moldings. Moreover, die castings are dimensionally stable, more heat resistant, and far superior to plastic moldings on both cost and properties basis. Die casting prevent electromagnetic and radio frequency emissions.
In the case of chrome plating, die casting is the superior method than plastic molding. When compared to plastic injection molding, die casting offer a high degree of permanence under load. Besides that, die casting is resistant to UV rays, stress cracking, and weathering in the presence of different agents.
Permanent Mold Castings
When compared to permanent mold castings, die-casting can be used to make castings of thinner sections and closer dimensional limits and can be made at higher rates with less labor. Permanent mold casting involve low tooling costs and can be manufactured with sand cores to offer shapes that are not available in die casting.
Sand Castings
Sand casting need more machining when compared to sand castings. Die casting can be made with thinner walls, have all the holes cored to size, produced rapidly in dies to make thousands of die casting without any replacement. It can be held with closer dimensional limits, without the need of new cores for each of the casting, and it offers smooth surfaces.
Sand casting can be made from ferrous and non-ferrous metals that are not suitable for die-casting. Shapes that cannot be made with die-casting can be manufactured with sand casting and can be used to make large castings that cannot be manufactured with die casting. Additionally, tooling cost is less for sand casting and can be used effectively and economically to make products in small quantities.
Forgings
Die casting can be used to make complex shapes that cannot be forged and have coring that is not possible in forging. However, forging is denser and stronger than die cast, with properties of wrought alloys, and can be made in ferrous or other metals and in sizes that cannot be made with die casting.