The process of die casting using pressure injection can be traced to mid 1800. The components that were used in the initial stages were tin and lead but their use tapered off with the introduction of alloys of zinc and aluminum. The process has evolved over the years from the low pressure injection techniques to the casting dies at pressures that can reach as high as 4500 psi. The processes are capable of creating high quality products that have excellent surface finishing.
Die casting is an economical yet effective process of creating a broad range of shapes. It is considered superior to other manufacturing technique and is considered durable and aesthetic, merging seamlessly with the other parts of the machinery of which it is a component. Die has many advantages and primary among them is its ability to deliver complex shapes with high levels of tolerance than any other mass production methods. Identical castings can be mass produced in thousands before you are required to add any new casting tools.
High pressure die is a manufacturing process in which the aluminum in its molten form is injected with a casting machine under extreme force, speed and pressure into a steel or mold to create parts of the desired shape and design. The rating of casting machines is in clamping tons universally. This rating reflects the amount of pressure exerted on the die. The size of the machine ranges from 400 to 4000 tons.
There are many benefits of using casting process over others. Die casting produces parts with thinner walls, closer limits of dimension and it is possible to speed up the process. Labor and finishing costs are the lowest with die. Complex shapes with closer tolerances can be easily achieved with this process. Unlike forging process, you can cast coring in products created through this process.
Shapes impossible to achieve from bar or tubular stock can be easily achieved with casting. The number of operation processes is less, leading to lower wastage of materials.
Die casting is used when you need parts that are dimensionally stable and durable. They are heat resistant and maintain good tolerance levels which are crucial pre-requisites for any good machinery parts. They are stronger and lighter than parts made by other casting methods. They do not have parts that are welded or bolted together, thereby immensely enhancing their efficacy. Another advantage is the multiple finishing that you can achieve with casting. The surfaces can either be smooth or textured providing ease of application and use.