Frequently Asked Questions (FAQs)
Die castings are produced by injecting molten alloys into custom-made reusable steel cavities, known as dies. The alloy solidifies within the die to create the desired component allowing for superior accuracy and repeatability.
Most dies are made with hardened tool steel machined into the net or near net shape die cast parts.
Some of the most popular die cast alloys are Aluminum, Zinc, Magnesium, Brass, and Copper. The strength of these materials creates a finished product with the rigidity and feel of metal and the high performance of expensive plastic and advanced composites. Fine details such as textured surfaces, names, or logos are quickly produced without costly post-processing.
Die casting can be produced in nearly every conceivable size and shape, from the smallest electronic component weighing less than one gram and requiring the most precise dimensions to the largest automotive parts that demand the toughest durability.
A complete die casting cycle can vary from less than a second for small components weighing less than an ounce to three minutes for casting several pounds. The speed makes die casting the fastest and most economical technique for producing precise non-ferrous net-shape components.
Die casting machines are typically rated by the clamping pressure they can exert on the die. Regardless of their type, the only fundamental differences in die casting machines are the methods used to inject molten metal into a die. Hot chamber machines are used for alloys with low melting temperatures, such as zinc. Cold chamber machines are used for alloys with high melting temperatures, such as aluminum.
Many modern products, such as metal enclosures, faucet parts, pistons, knobs, filter housings, microwave components, etc., are created through die casting processes.
The North American Die Casting Association (NADCA) is a trade organization representing North America’s die casting industry. NADCA has developed a set of industry standards that are widely used by die casting companies and their customers. These standards cover various topics related to die casting, including materials, process control, and quality assurance. They are an essential resource for die casting companies and their customers, helping to ensure that the die casting process is performed consistently, efficiently, and to a high level of quality.