Die casting is a highly efficient manufacturing process that involves injecting liquified metal alloys into a reusable mold using extreme pressure. The process is fast, automatable, and produces high volumes of identical components. In this article, we will explore the six most common types of die casting, their advantages, and some popular applications for die-casted parts.
The process of high pressure die casting (HPDC) is widely used to create metal components that meet or exceed industry standards for accuracy, longevity, and strength.
High-pressure direct casting (HPDC) involves injecting molten metal into a reusable steel mold at high pressure to create components for a variety of industries. In this piece, we’ll discuss the advantages of HPDC components, offer some examples, and offer some data on the topic.
High-pressure die-casting has many advantages.
Great Precision: HPDC is widely used for complex geometries and tight tolerances because to its reputation for creating products with great dimensional precision.
HPDC components are known for their strength and durability because of their superior mechanical qualities, which make them resistant to wear, fatigue, and impact.
HPDC is a cost-effective manufacturing technology because of its high production rates and little material waste.
HPDC’s versatility lies in the fact that it may be used to manufacture everything from tiny components to massive structural beams.
Case Studies of High Pressure Die Casting
One of the world’s largest automakers contracted HPDC to make components for their engine management systems. They were able to increase efficiency and decrease emissions by using HPDC to attain high precision and tight tolerances.
Manufacturing strong yet lightweight components for airplane motors was a priority for a parts manufacturer in the aerospace sector. HPDC allowed them to make lighter, stronger, and more fuel-efficient pieces by reducing material thickness without sacrificing mechanical qualities like stiffness and strength.
Consumer Electronics: A maker of smart home devices required the production of intricate and microscopic components. The great precision and low porosity they were able to accomplish using HPDC enabled for long-lasting, dependable, and simple-to-assemble components.
Statistics: High Pressure Die Casting
At a compound annual growth rate (CAGR) of 8.8% from 2020 to 2025, the global HPDC market is forecast to reach USD 39.93 billion by 2025. According to MarketsandMarkets.com,
More than 35% of the 2020 market share for HPDC is expected to come from the automotive industry. According to (Grand View) Research
More than 70% of the HPDC market share in 2020 will be accounted for by aluminum. According to (Grand View) Research
Types of Die Casting
There are six types of die casting, each with its unique advantages and applications. They include:
- Aluminum Die Casting: Ideal for intricate parts, aluminum is strong, durable, and lightweight. Its cold-chamber die casting process reduces the risk of corrosion and eliminates the need for finishing or secondary processes.
- Zinc Die Casting: Zinc’s hot-chamber process allows for the creation of thin, intricate parts that are highly resistant to corrosion and have excellent formability and castability.
- Low-Pressure Die Casting: This process creates high-yield batches of symmetric, circular aluminum parts, such as vehicle wheels.
- Vacuum Die Casting: Used for parts that require heat-based finishing treatments, vacuum die casting processes reduce turbulence and gas inclusions in the resulting components.
- Squeeze Die Casting: Ideal for metals with low fluidity, this process produces stronger fibers and less fluidity in molten aluminum parts.
- Semi-Solid Die Casting: For maximum density and virtually no porosity and turbulence, semi-solid die casting is ideal for non-ferrous metals like aluminum and magnesium.
Applications of Die Casting
Die casting finds use in various industries, including:
- Appliances: Die casting creates highly precise components that are ideal for small, compact configurations of moving parts.
- Automotive: Die-casted metal parts increase fuel efficiency and performance while reducing weight.
- Electric Motors: Aluminum parts are strong yet lightweight, making them ideal for EV motors.
- Hand Tools: Die-cast parts are strong, durable, and have safe edges without requiring finishing or secondary processes.
- Robotic Automation: Complex and flexible robots require precise, lightweight components that allow for complex motions.
- Security Components: Die casting works with a variety of metals, allowing manufacturers to create everything from lightweight electronic security components to heavy-duty locks and tumblers.
Die Casting at Castingod
At Castingod, we specialize in full-service aluminum and zinc die casting projects. Our design and engineering professionals can help you find the right process and materials for your die-cast design. We prioritize customer satisfaction through excellent customer service, cost-effective services, expertise, and complete engineering support from start to finish. Contact us today to learn more about our capabilities or request a quote for pricing details.
