Many manufacturers choose die casting to mold metals into desired shapes because this process offers a high degree of uniformity, quality surface finishes, and close design accuracy to the finished products. In several instances, die casting also help manufacturers to eliminate or reduce the need for post-production machining.
This in turn shortens the fabrication time and considerably increases the cost efficiency of the metal molding process. However, it might be a little bit difficult to die cast sturdier metals like certain grades of Steel. This is the reason why manufacturers prefer other casting methods for sturdier metals.
Die casting molds are generally constructed from hardened Steel and these components are one of the most expensive components in a die casting machine. These molds are capable of handling a different range of alloys, but die casting is a lot more effective on metals that have low fusing temperatures. Below are some of the most common alloys that are used by die casting companies.
Zinc Alloys
Many manufacturers claim that Zinc-based materials are comparatively easy to die cast and they respond exceptionally well to the casting process. Zinc-based materials consist of more than a few metals in certain ratios. For instance, a usual Zinc-based die casting alloy contains 86 percent Zinc, 7 to 10 percent Tin, and 4 to 7 percent Copper.
Tin Alloys
Alloys that are composed with a considerable amount of Tin as a base material are commonly used in applications, which require corrosion resistance. The proportion of metals in Tin alloys may vary significantly, but a Tin alloy usually consists of a 90 percent Tin, 4 percent Copper, and 6 percent Antimony.
Bronze and Brass Alloys
Most of the Brass and Bronze alloys respond well to the die casting process and they are commonly used to create decorative products, camshaft components, and washers. The major components of a typical Brass alloy are Zinc and Copper.
Aluminum Alloys
Die cast Aluminum alloys are usually found in gears and automobile parts and they were also used for the creation of surgical instruments in the past. Aluminum alloys are generally lighter and stronger than Zinc-based materials, but they could be a little bit expensive to create.
Lead Alloys
Lead alloys are mainly used in applications that require less than 8000 pounds of tensile strength per square inch. Some of common applications include bearings, decorative metal goods and fire-safety equipments. Lead alloys are comparatively inexpensive for producing castings.