Die casting is a metal shaping or manufacturing process, which is specifically used for producing geometrically complex metal parts by using reusable molds, known as dies. Die casters incorporate the use of a die casting machine, furnace metal, and die to create metal parts with desired shapes and properties.
A wide variety of different die casting metal choices are available to die casters when they are designing metal parts through the process of die casting. Beginners who do not have a clear idea on the metal shaping process of die casting will find it very difficult to identify the right metal for different die casting processes.
Choosing a Metal for Die Casting Process
The metals and alloys that are used for die casting usually have unique physical characteristics. So, you will need to examine the physical properties of each metal and alloy. This will not only enable you to find the alloy or metal that is suitable for your preferred die casting process but also help you to produce the desired metal parts with superior properties.
Die casters usually check the mechanical properties of alloys and metals before selecting a certain die. The tensile strength, impact strength, yield strength, elongation properties, and hardness of the metal are thoroughly examined by die casters to find the metal that is suitable for the specific die casting process.
In addition to that, most die cast aluminum companies will also check the physical properties of the metal including conductivity. Die casters will also examine how the metal or alloy will respond when it is exposed to extreme pressure or temperature conditions. This will help them to tell whether the metal is capable of undergoing the process or not.
Before selecting a certain metal for the die casting process, die casting companies usually examine the composition of different alloys in the die. Once they have examined the different characteristics of different metals and alloys, they will choose a metal with excellent physical and mechanical properties.
Types of Die Casting Metals
Zinc, aluminum, and magnesium are the top three metal choices of expert die casters when they are creating metals with desired shapes with the help of die casting. The excellent physical and mechanical properties of these three metals enables die casters to easily produce finished products with superior characteristics. In some cases, the metals in its pure form might not be that hard or strong, which makes unsuitable for die casting.
In such cases, die casters mix the pure metal with a few alloys in order to make it strong and hard enough. For instance, magnesium in its pure form is soft. So, die casters mix magnesium with aluminum, zinc, manganese, or silicon to improve its physical and mechanical properties. This in turn makes the resultant metal alloy combination well capable of undergoing the process of die casting.
In some rare cases, die cast aluminum companies use lead, tin, brass, and copper alloys as dies. Most of these alloys are rarely used by die casters. However, when they want to produce metal shapes with different shapes and properties as per the requirements of customers, die casters are forced to rely on these alloys.
Die Casting Metal for Making Vehicle Parts
Die casters who are designing metal parts for RVs, trucks, and other vehicles usually use the alloys of zinc and aluminum for the die casting process. Even though aluminum alloys are relatively a bit expensive, they continue to be the most favored choice of die casters when they are designing gears and metal parts for truck and other vehicles.
Most of the aluminum alloys have exceptional corrosion resistance along with a good strength to weight ratio. In addition to that, these alloys are extremely lightweight, which in turn guarantees better mileage for RVs and trucks. The high thermal and electrical conductivity properties of aluminum make them an ideal choice for casting in the computing, electrical, and lighting field.
Die Casting Metals for Medical Equipments
The metals that are used by die casters for making medical equipment will significantly vary based on the type of the equipment that you are designing. However, aluminum, magnesium, and zinc are usually the most commonly used metals when it comes to medical equipment die casting. Out of these three, zinc is more commonly used by die casters, as it is quite durable, strong, and hard.
If the medical equipment is a patient-facing device, which requires an attractive plated or painted finish, then die casters use zinc. This is because zinc offers a smooth surface to work on for die casters and it can also be plated a lot easier than aluminum die castings. Die casters are also able to design thin walled parts due to the excellent properties of zinc, which is important when weight is one of the important factors in a certain application.