What Is Die Casting?

For components with complex geometries and that require high yearly volumes, Die Casting can be considered very cost effective and versatile.

Usually, once you reach an average yearly volume of 15,000 parts, it’s a good time to consider zinc die casting.

If you are processing less than this, you may want to first consider graphite permanent molding or sand casting.

What does Die Casting involve?

Because die casting is a net-shape process, eliminating secondary machining and assembly options (typically unavoidable in other processes) allows for cost savings.  In the conversion process from other methods to zinc die casting, multiple parts can be redesigned to form one, net shape die cast component.

Hot Chamber vs. Cold Chamber Die Casting

Hot Chamber die casting is used for alloys with low melting temperatures and a low attack rate on steel components. In the case of the majority of zinc die casting alloys, hot chamber is used. It is more economical.

It is known as hot chamber because the gooseneck (metal pump) is immersed in molten zinc alloy, pumping metal directly from the furnace to the die. Hot chamber generally has faster cycle times, lower processing costs and smaller runner systems than cold chamber die casting.

Zamak 3 is a top alloy choice in the USA, because of a combination of favorable properties, castability and low cost.

The only difference in cold chamber casting is that the molten metal is poured into a horizontal cylinder before being injected into the mold. Alloys with a higher attack rate on iron and steel components, such as Aluminium alloys and ZA-12 / ZA-27 zinc alloys require cold chamber processing.

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