The metal shaping process of die casting is one of the most versatile and cost-effective manufacturing processes. The precision process, die casting consists of forcing a molten metal into a mold or die of the desired shape under high-temperature conditions. Most of the dies are generally constructed by using long lasting quality steel materials.
One of the most vital choices die casting companies will have to make before they die cast a specific design is to determine the type of alloy that is best suited for the application. The popular types of metallic alloys that are used in the die casting process are zinc-aluminum, zinc, magnesium, and aluminum.
Each of these alloys has their own mechanical and physical properties. These properties of the alloys are significant factors in determining the strength, overall functionality, and strength of the final or finished product. Die casting companies generally use alloys that have lower melting temperatures. However, the required precision, complexity, and the minimum wall thickness of the part will also have a big influence on the castability of the alloy.
Die casters implement several types of metal casting methods based on the metal allow used and the applications of the design. Some of the most common die casting methods include the squeeze casting, cold chamber, and hot chamber processes.
Hot chamber die casting process is the ideal choice for metals with low melting temperature such as magnesium and zinc, whereas the cold chamber process is typically used for metal alloys with higher melting temperatures including aluminum. On the other hand, squeeze casting process doesn’t need any gas entrapment but it still creates high-quality finishing materials.
Aluminum is not as castable as zinc because of its higher melting temperature. However, aluminum alloys are still one of the most commonly used alloys in many die casting companies across the world. Besides, aluminum alloys are also economic, which is the reason why they are used in high-volume casting projects.
Magnesium alloys are another type of lightweight structural material that is commonly used in die casting processes. Die caster alloys magnesium with other metals in order to provide better mechanical properties and greater stability to the finished product. The selection of the alloys for the die casting will depend on the requirements of the finished product.