Die casting is a versatile process for

producing engineered metal parts by
forcing molten metal under high pressure
into reusable steel molds. These molds,
called dies, can be designed to produce
complex shapes with a high degree of
accuracy and repeatability. Parts can be
sharply defined, with smooth or textured
surfaces, and are suitable for a wide
variety of attractive and serviceable
finishes.
Die castings are among the highest
volume, mass-produced items
manufactured by the metalworking
industry, and they can be found in
thousands of consumer, commercial
and industrial products. Die cast
parts are important components of
products ranging from automobiles
to toys. Parts can be as simple as a
sink faucet or as complex as a
connector housing
 i

The earliest examples of die casting by
pressure injection - as opposed to casting by
gravity pressure - occurred in the mid-
1800s. A patent was awarded to Sturges in
1849 for the first manually operated machine
for casting printing type. The process was
limited to printer¶s type for the next 20
years, but development of other shapes
began to increase toward the end of the
century. By 1892, commercial applications
included parts for phonographs and cash
registers, and mass production of many
types of parts began in the early 1900s.
The first die casting alloys were various
compositions of tin and lead, but their use
declined with the introduction of zinc and
aluminum alloys in 1914. Magnesium and copper
alloys quickly followed, and by the 1930s, many
of the modern alloys still in use today became
available.The die casting process has evolved
from the original low-pressure injection method
to techniques including high-pressure casting ²
at forces exceeding 4500 pounds per square inch
² squeeze casting and semi-solid die casting.
These modern processes are capable of
producing high integrity, near net-shape
castings with excellent surface finishes.
u



Äefinements continue in both the alloys used in
die casting and the process itself, expanding die
casting applications into almost every known
market. Once limited to simple lead type, today¶s
die casters can produce castings in a variety of
sizes, shapes and wall thick nesses that are
strong, durable and dimensionally precise.
u



 

 
Die casting is an efficient, economical process
offering a broader range of shapes and
components than any other manufacturing
technique. Parts have long service life and may
be designed to complement the visual appeal of
the surrounding part. Designers can gain a
number of advantages and benefits by specifying
die cast parts.
i 

 
  Die casting provides
complex shapes within closer tolerances than many
other mass production processes. Little or no
machining is required and thousands of identical
castings can be produced before additional tooling is
required.


     

 Die casting

produces parts that are durable and dimensionally
stable, while maintaining close tolerances. They are
also heat resistant.
˜


  

 Die cast parts are stronger
than plastic injection moldings having the same
dimensions. Thin wall castings are stronger and
lighter than those possible with other casting
methods. Plus, because die castings do not consist of
separate parts welded or fastened together, the
strength is that of the alloy rather than the joining
process.


   

 
  Die cast parts can
be produced with smooth or textured surfaces, and
they are easily plated or finished with a minimum of
surface preparation.
˜ 
 
  Die castings provide integral
fastening elements, such as bosses and studs. Holes
can be cored and made to tap drill sizes, or external
threads can be cast.


  

The basic die casting process consists of injecting
molten metal under high pressure into a steel mold
called a die. Die casting machines are typically rated
in clamping tons equal to the amount of pressure
they can exert on the die. Machine sizes range from
400 tons to 4000 tons. Äegardless of their size, the
only fundamental difference in die casting machines
is the method used to inject molten metal into a die.
The two methods are hot chamber or cold chamber.
A complete die casting cycle can vary from less than
one second for small components weighing less than
an ounce, to two-to-three minutes for a casting of
several pounds, making die casting the fastest
technique available for producing precise non-ferrous
metal parts.


 







 
 
    Die casting produces
stronger parts with closer tolerances that have greater
stability and durability. Die cast parts have greater
resistance to temperature extremes and superior
electrical properties.


 
   
   Die casting produces
parts with thinner walls, closer dimensional limits and
smoother surfaces. Production is faster and labor costs
per casting are lower. Finishing costs are also less.


 
 


  Die casting offers
the same advantages versus permanent molding as it
does compared with sand casting.


 
    Die casting produces more
complex shapes with closer tolerances, thinner walls and
lower finishing costs. Cast coring holes are not available
with forging.


 
 
   Die casting produces
complex shapes with variations possible in section
thickness. One casting may replace several stampings,
resulting in reduced assembly time.


 
 
  

 - Die casting
produces shapes that are difficult or impossible from bar
or tubular stock, while maintaining tolerances without
tooling adjustments. Die casting requires fewer
operations and reduces waste and scrap.
  



vach of the metal alloys available for die casting offer particular
advantages for the completed part.
   The easiest alloy to cast, it offers high ductability, high impact
strength and is easily platable. Zinc is economical for small parts, has
a low melting point and promotes long die life.
   This alloy is lightweight, while possessing high
dimensional stability for complex shapes and thin walls. Aluminum
has good corrosion resistance and mechanical properties, high
thermal and electrical conductivity, as well as strength at high
temperatures.

  The easiest alloy to machine, magnesium has an
excellent strength-to-weight ratio and is the lightest alloy commonly
die cast.

  This alloy possesses high hardness, high corrosion
resistance and the highest mechanical properties of alloys cast. It
offers excellent wear resistance and dimensional stability, with
strength approaching that of steel parts.

   u  These alloys offer high density and are capable of

producing parts with extremely close dimensions. They are also used
for special forms of corrosion resistance.
 K


K
  



 
 


Dimensional stability Good Excellent Excellent ood

Korrosion resistance ood Excellent Fair Fair

Kasting ease ood Fair Good Excellent

Part complexity ood Fair Good Excellent

Dimensional accuracy ood Fair Excellent Excellent

Die cost Medium High Medium Low

Machining cost Low Medium Low Low

Finishing cost Medium Low High Low

K
 
 

  
  







  



 




 ÿ
 

 

 
  

 

 


 
 

Maximum weight, lb. 70 10 44 75

Minimum wall thickness, large casting, in. 0.080 0.090 0.100 0.035

Minimum wall thickness, small casting, inc. 0.040 0.055 0.040 0.015

Minimum variation per in. of diameter or

0.0015 0.009 0.0015 0.001
length from drawing dimensions over one in.

Kast threads, max. per in. external 24 10 24 32

Kored holes, min. diameter in. 0.080 0.250 0.080 0.050

 h   


 


 
 

Khrome plating Fair Excellent Fair Excellent

Black chrome plating Fair Excellent ࣘ Excellent

Kolored plating Fair ࣘ ࣘ Excellent

Mechanical - polishing & buffing Excellent Excellent Excellent Excellent

Lacquers, enamels, epoxies & acrylics Excellent Excellent Excellent Excellent

Anodizing Fair ࣘ ࣘ ࣘ
  
 
 

uensile strength, psi x 1000 47 55 34 41

Yield strength, psi x 23 30 23 ࣘ

Shear strength, psi x 1000 28 37 20 31

Fatigue strength, psi x 1000 20 25 14 7

Elongation, pct in 2 in. 3.50 15 3.0 10

Hardness (Brinell) 80 91 63 82

Specific gravity 2.71 8.30 1.80 6.60

Weight, lb/cu. in. 0.098 0.305 0.066 0.24

Melting point (liquid), °F 1100 1670 1105 728

uhermal conductivity, KG5 0.23 0.21 0.16 0.27

uhermal expansion, in./in./°F x 106 12.1 12.0 15.0 15.2

Electrical conductivity 27 20 10 27

Modulus of elasticity, psi x 106 10.3 15 6.5 ࣘ

Impact strength (Kharpy), ft/lb 3.0 40 2.0 43.0

 


˜
Aluminum die casting alloys are lightweight, offer good corrosion
resistance, ease of casting, good mechanical properties and
dimensional stability.
Although a variety of aluminum alloys made from primary or recycled
metal can be die cast, most designers select standard alloys listed
below:

  Selected for best corrosion resistance. Special alloys for
special applications are available, but their use usually entails
significant cost premiums.
  An alloy which provides the best combination of utility and
cost.
    These alloys are a modification of 380. Both provide
better die filling, but with a moderate sacrifice in mechanical
properties, such as toughness.
  Selected for special applications where high strength, fluidity
and wear-resistance/bearing properties are required.
   Used for maximum pressure tightness and fluidity.
 
  


Machine Types:    
  

Hot chamber (Plunger) No No Yes Yes

Cold chamber Yes Yes Yes Yes

Production range, shots/hr 40-200 40-200 75-400 200-550

Average tool life, no. of shots x 1000 125 20 200 500

  


 

  

   
  


Dimensional stability ood vxcellent vxcellent ood

Corrosion resistance ood vxcellent Fair Fair

Casting ease ood Fair ood vxcellent

Part complexity ood Fair ood vxcellent

Dimensional accuracy ood Fair vxcellent vxcellent

Die cost Medium High Medium Low

Machining cost Low Medium Low Low

Finishing cost Medium Low High Low

  u˜ ˜u
Die casting component parts, decorative trim, and/or finished
products offer many features, advantages and benefits to
those who specify this manufacturing process.
‡Die casting provides complex shapes within closer
tolerances than many other mass production processes.

‡Die castings are produced at high rates of production.

Little or no machining is required.

‡Die castings can be produced with thinner walls than those

obtainable by other casting methods ... and much stronger
than plastic injection moldings with the same dimensions.

‡Die casting provide parts which are durable, dimensionally

stable, and have the feel and appearance of quality.

‡Die casting dies can produce thousands of identical

castings within specified tolerances before additional tooling
may be required.
‡ Zinc castings can be easily plated or finished with a
minimum of surface preparation.
‡ Die cast surfaces, as cast, are smoother than most
other forms of casting.
‡ Die castings can be produced with surfaces simulating
a wide variety of textures.
‡ Holes in die castings can be cored, and made to tap
drill sizes.
‡ vxternal threads on parts can be readily die cast.
‡ Die castings provide integral fastening elements, such
as bosses and studs, which can result in assembly
economies.
‡ Inserts of other metals and some non-metals can be
die cast in place.
‡ Corrosion resistance of die casting alloys rates from
good to high.
i
 

Hot chamber or plunger machines are used mainly for zinc
alloys. With modern technology, this process is increasingly
being used for magnesium. The hot chamber process is a
preferred die casting method due to its high rate of
productivity. However, it cannot be used for some high melting
point alloys or for those alloys which attack the steel working
parts of the machine.
Operating sequence for the hot chamber die casting process:
1. Die is closed and gooseneck cylinder is filled with molten
metal.
2. Plunger pushes molten metal through gooseneck passage
and nozzle and into the die cavity. Metal is held under pressure
until it solidifies.
3. Die opens and cores, if any, retract. Casting stays in ejector
die. Plunger returns, pulling molten metal back through nozzle
and gooseneck.
4. vjector pins push casting out of ejector die. As plunger
uncovers inlet hole, molten metal refills gooseneck cylinder.
  

Cold chamber machines minimize contact between the alloy to
be cast and steel machine parts which allows the processing of
high melting temperature alloys. Its primary use is for
aluminum, brass, and larger magnesium die castings.

Operating sequence for the cold chamber die casting process:

1. Die is closed and molten metal is ladled into the cold
chamber cylinder.
2. Plunger pushes molten metal into die cavity. the metal is
held under high pressure until it solidifies.
3. Die opens and plunger follows to push the solidified slug
from the cylinder. Cores, if any, retract.
4. vjector pins push casting off ejector die and plunger returns
to original position.
Advice on designing die castings is
usually based upon desirable practices
or situations to avoid. However, like
most rules, there are exceptions.
These affect either costs, appearance
and/or quality of final products. Listed
below are guides which should be
considered when designing for die
casting:
‡Specify thin sections which can easily be die cast and
still provide adequate strength and stiffness. Use ribs
wherever possible to attain maximum strength,
minimum weight.
‡Keep sections as uniform as possible. Where sections
must be varied, make transitions gradual to avoid
stress concentration.
‡Keep shapes simple and avoid nonessential
projections.
‡A slight crown is more desirable than a large flat
surface, especially on plated or highly finished parts
‡Specify coring for holes or recesses where savings in
metal and overall costs outweigh tooling costs.
‡Design cores for easy withdrawal to avoid
complicated die construction and operation.
‡Avoid small cores. They can be easily bent or broken
necessitating frequent replacement. Drilling or piercing
small holes in die castings is often cheaper than the
cost of maintaining small cores.
‡Avoid use of undercuts which increase die or
operating costs unless savings in metal or other
advantages fully warrant these extra costs.
‡Provide sufficient draft on side walls and cores to
permit easy removal of the die casting from the die
without distortion.
‡Provide fillets at all inside corners and avoid sharp
outside corners. Deviation from this practice may be
warranted by special considerations
‡Die casting design must provide for location of
ejector pins. Take into consideration the effect of
resultant ejector marks on appearance and function.
The location of ejector pins is largely determined by
the location and magnitude of metal shrinkage on die
parts as metal cools in the die.
‡Specify die cast threads over cut threads when a net
savings will result.
‡Die castings which affect the appearance of a finished
product may be designed for aesthetics, and to
harmonize with mating parts.
‡Inserts should be designed to be held firmly in place
with proper anchorage provided to retain them in the
die casting.
‡Design parts to minimize flash removal costs.
‡Never specify dimensional tolerances closer than
essential. This increases costs.
‡Design die castings to minimize machining.
‡Where machining is specified, allow sufficient metal
for required cuts.
‡Consider contact areas for surfaces which are to be
polished or buffed. Avoid deep recesses and sharp
edges.


  Industry term commonly used to describe
the mechanization of various aspects of the die casting
process.

 vxcess of ladled metal remaining in the shot
sleeve of a cold chamber die casting machine. It is part of
the cast shot and is removed from the die with the casting.


 A surface bubble caused by gas expansion
(usually from heating) which was trapped within the die
casting or beneath the plating.
 
 Voids or pores which may occur due to
entrapped gas or shrinkage during solidification, usually
evident in heavy sections (see porosity).


 The recess or impressions in a die in which the
casting is formed.
 
 
 A type of casting machine in
which the metal injection mechanism is not submerged in
molten metal.

  Fine cracks on the surface of a die which produce
corresponding raised veins on die castings. Caused by repeated
heating of the die surface by injected molten alloys.


 Plastic deformation of metals held for long periods at
stresses lower than yield strength.


 Liquid formulations applied to the die to facilitate
casting release and prevent soldering.

 

 Ability of a component to retain its shape
and size over a long period in service.

  A guide pin which assures registry between cavities in
two die halves.

 The taper given to walls, cores and other parts of the die
cavity to permit easy ejection of the casting.


 Marks left on castings by ejector pins.




 A plate to which ejector pins are attached and which
actuates them.


 Curved junction of two surfaces, e.g., walls which would
meet at a sharp angle.
  A thin web or fin of metal on a casting which occurs at die
partings, vents and around moveable cores. This excess metal is due
to working and operating clearances in a die.


 Passage for molten metal which connects runner with die
cavity. Also, the entire ejected content of a die, including castings,
gates, runners, sprue (or biscuit) and flash.


 Spout connecting a metal pot or chamber with a
nozzle or sprue hole in the die and containing a passage through
which molten metal is forced on its way to the die. It is the metal
injection mechanism in a hot chamber type of die casting machine.

 vxpansion of a casting as a result of aging or of
intergranular corrosion, or both.
i


  (See checking)
i
 
 
 Die casting machines which have the
plunger, gooseneck (metal pressure chamber) immersed in molten
metal in the holding furnace.
i
 
 Term used to describe an alloy which is brittle or lacks
strength at elevated temperatures.




 Ability to resist shock, as measured by a suitable
testing machine.

  Cavity in a die. Also, the mark or recess left by a ball,
or penetrator of a hardness tester.
 
 Metal or alloy cast in a convenient shape for storage,
shipping and remelting.
 

  The process of forcing molten metal into a die.
 

 A piece of material, usually metal, which is placed in a die
before each shot. When molten metal is cast around it, it becomes an
integral part of the die casting.


   A type of corrosion which preferentially
attacks grain boundaries of metals or alloys, resulting in deep
penetration.




 
 A type of core (which forms undercuts)

which is positioned in, but not fastened to a die. It is so arranged as
to be ejected with the casting and from which it is removed. It is
used repeatedly for the same purpose.




 Core used primarily to reduce amount of metal in a
casting and to avoid sections of excessive thickness.





 A die having more than one duplicate
impression.

 Outlet end of a gooseneck or the tubular fitting which joins
the gooseneck to the sprue hole.


 
 A recess in a die connected to a die cavity by a
gate to assist in proper venting.

 
 A mark left on a die casting where the die halves
meet; also, the mating surface of the cover and ejector portions of
the die.
 
 Äam or piston which forces molten metal into a die.

 Opening through which molten metal enters the injection
cylinder.

 Voids or pores resulting from trapped gas, or shrinkage
during solidification.


 Where parameters of a process are studied and
correctly applied in the manufacturing process to produce high
quality parts.

 Die passage connecting sprue or plunger holes of a die to
the gate where molten metal enters the cavity or cavities.
˜ 
 That segment of the casting cycle in which molten metal is
forced into the die.
˜  
 
  Dimensional reduction that
accompanies the freezing (solidification) of metal passing from the
molten to the solid state.
˜   A surface depression which sometimes occurs next to
a heavy section that cools more slowly than adjacent areas.
˜
 The portion of the die arranged to move parallel to die
parting. The inner end forms a part of the die cavity wall that
involves one or more undercuts and sometimes includes a core or
cores.
˜
  Adherence of molten metal to portions of the die.
˜


 A gate of castings having the sprue or plunger axis in
the die parting.
˜
 Metal that fills the conical passage (sprue hole) which
connects the nozzle with runners.
˜
  A tapered pin with rounded end projecting into a sprue
hole and acting as a core which deflects metal and aids in the
removal of the sprue.
u
 Linkage employed to mechanically multiply pressure when
locking the dies of a casting machine.
u
 A die for shearing or shaving flash from a die casting.
 

 A die interchangeable with others in a common holder.
 

 Äecess in the side wall or cored hole of a casting
disposed so that a slide or special form of core (such as a knockout)
is required to permit ejection of the casting from the die.


 Narrow passage at the die parting which permits air to
escape from the die cavity as it is filled with molten metal.
 A large pore or hole within the wall of a casting usually
caused by entrapped gas. A blow hole.



 A tube or passage through which water is circulated to
cool a casting die.