Reduce Fabrication Costs with Precision Castings

Product manufacturers are constantly looking for ways they can use to reduce the manufacturing casts. Precision castings offer an efficient technique to decrease expenses related to fabrication and machining. Wondering how this process can be economical in the long run?

You can save a lot of money, if you are clear about what you want when the cast design is being prepared. By incorporating many features of the tool design in the casting design, you will be able to save on a lot of extra work and resource. Discuss the design with the engineers to find ways in which the cast design can be optimized to give you better results and stronger casts. In case you want to have the logo or date on the part produced, you can incorporate it in the design itself. So, you don’t have to separately stamp the details on the product after it comes out of the cast.

The metal alloy you choose for the precision castings will also play a major role in determining your production expenses. You will have to choose the best metal alloy for the product based on the features of the element and the purpose of the finished product. If the finished product has to withstand a lot of stress and pressure, then you can choose aluminium alloy for casting. On the other hand, if the finished product has to be lightweight, then magnesium or tin alloys will be perfect for the job. Based on the metal alloy selected, you can alter the temperature, pressure and other conditions during precision castings. By determining the conditions in which the casting is done, the cast can be customized for optimum results. Also, for some metal alloys like zinc and aluminium, you don’t need to spend a lot on finishing. It is because the metal alloy itself has a good finishing, which will be reflected in the metal cast you make. So, you get maximum returns for the money you put in.

Unused casts can be recycled and used again. This is one way in which precision casting helps save you more money. If a cast has come out wrong or broke while removing from the cast, you don’t have to throw it into the bin. Again while finishing or polishing, some pieces of cast may fall. Put all the wastes in the kiln, melt the metal and reuse it again. In a production process, where there is absolutely no chance of wastage, how can one not save money?

An Insight into Magnesium Die Casting

It was during the industrial era that the scientific community and manufacturers worked hand in hand to create processes that could be used for mass production of products. Many new inventions and plenty of advanced technologies were developed during this period of time. These manufacturing processes have been fine-tuned and optimized over years in order to maximize production and reduce costs. One such technique that revolutionized the manufacturing industry is magnesium die casting.

In layman’s terms, die casting is a process that involves forcing hot molten metal into a mould and allowing it to cool. When the magnesium alloy cools, it takes up the shape of the cast. Then the cast can be removed to release the manufactured part. This method may seem to sound very simple, but there are lots of factors that the manufacturers have to be taken into consideration when the manufacturers set up the entire unit for magnesium die casting.

It is not just magnesium alloy that is used for die casting. A variety of non-ferrous metals such as zinc, aluminium, tin and their alloys are also used in this technique. The choice of the metal alloy and other manufacturing conditions depends on the process and the product. The casting time and the amount of material required depends on the die cast design and process flow. If properly planned and executed, the die casting process can be used to mass produce products without loss of quality or waste of raw material.

Magnesium die casting is preferred for many product manufacturing processes as it is lightweight yet strong. This alloy is used in the production of parts and components for automobiles, hand tools and scores of other appliances. This alloy is also preferred for processes in which the operating temperature is more than 120 degree Celsius. Even if the alloy is cast at such high temperature, its surface flatness and bolt tension is maintained. So, you will get superior quality results each time.

When compared to other casting metals, magnesium alloy offers greater corrosion resistance and better machining. Moreover, this metal alloy has high conductivity, superior dimensional stability and stiffness. So, manufacturers can use this metal alloy for processes that involve casting wafer thin wall products.

After magnesium die casting process is completed, the components can be painted or powder coated. However, the casts will require pre-treatment in order to ensure proper adhesion and smooth results. 

Types of Die Casting Processes

A metal casting process used in most manufacturing processes, die casting offers an efficient and cost-effective method to produce large volumes of high-quality products. This technique is used in the manufacture of small to mid-sized metal spare parts. Die casting is basically a simple process that involves pouring molten metal into a pre-designed cast. As the metal solidifies, it moulds into the shape of the cast, which can then be easily removed from the cast and used. The important factors that determine the quality of the finished product of die casting are the raw material, temperature, solidification time and die casting process. The two popular metal alloys used for die casting are zinc alloy and aluminium.

Let’s take a look at the different processes of die casting and how they affect the quality of finished product.

Cold-Chamber Die Casting Process

This process is commonly used for aluminium die casting. In this method, metal alloy is first melted in a furnace, and then it is manually or automatically poured into the injection system, which then passes on to the cast. It is a very slow method, which may be its only disadvantage. But, on the other hand, this technique is very effective for corrosive applications and for casting metal alloys with high melting points.

Hot-Chamber Die Casting Process

Also known as gooseneck casting, the hot-chamber die casting process is popularly used in most manufacturing units. It is called as gooseneck casting process because the technique involves the injected molten metal flowing through a gooseneck feed system into the cavity of the cast. This technique is best suited for metal alloys with high fluidity and low melting point. It is most commonly used for zinc metal casting, though other metals such as copper, lead and magnesium are also cast using this technique.

Low-Pressure Die Casting Process

This aluminium die casting technique is used when large volumes of parts have to be manufactured. In this process the mould is placed above the metal bath, and a riser tube connects the two. Pressure is applied in the chamber, which pushes the molten metal towards the cast on top.

Vacuum Die Casting Process

A die casting process similar to low-pressure die casting, this technique involves creating a vacuum in the cavity to force the molten metal into the riser tube and the cast placed on top. An advantage of this technique is that it prevents the formation of gas inclusions during the zinc die casting process.

Uniformity Dwells in Die Casting Design

Any tool manufacturing company, be it an automobile, gadget or toy making companies are involved in mass production for which uniformity is of prime importance. With respect to size, shape, structure, calibration, etc., one can hardly find any difference. The basic concept behind this uniformity is a die that is used for manufacturing. Every product is designed with high accuracy and with finished surface with the help of die casting. The use of die casting is cost effective as it nearly eliminates the need of refinishing or scraping any part. The assembly line is reduced, resulting in cost efficiency and reduction in assembly time. All this can be made possible with the use of suitable die casting design.  

 

Let us basically focus on the concept of die casting. The furnace is used for die casting in which the metal is melted. And this molten metal is forced under pressure into a cavity of mold. This mold is made with the use of two steel dies which are hardened. These molds are shaped into the required die casting design. These dies are designed in such a way that it can produce any required shape, be it complex or the simplest. But the outcome is accurate and uniform. Though the process to make parts with the use of die casting is simple the metal dies and casting machines involve huge capital cost. Thus, there is a need of mass production.

 

Non-ferrous metals or alloys of metals like zinc, aluminum, copper, magnesium, tin or lead are used to make the die casting. The process of die casting involves two types of machines viz. hot chamber machine and cold chamber machine. Hot chamber machines are used for alloys having a low melting point like zinc, lead and tin, whereas cold chamber machines are used for alloys like aluminum, copper and magnesium that has a high melting point. Once the molten metal gets injected into these molds, it cools down and attains solid state on these machines which is known as the casting. The process of direct injection is used for making zinc alloy die casting so as to get fine surface and better finishing. The plating zinc alloy is essential as it can undergo corrosion when exposed to salt water. Hence, it has to be coated in order to maintain its luster.  

Instead of brass or iron cast, zinc alloys are always preferred, though its tensile strength is lower. Its melting point is around 800 degree Fahrenheit. Zinc alloy die casting is highly beneficial as it has a low melting point and die casting using zinc alloy is easy to fabricate as it is highly ductile. It can be coated with ease and the final outcome is flawless and can retain its luster for longer period. 

Aluminium Die Casting – Efficient, Durable and Versatile

Metal die casting is a process that is being used in a number of industries for efficient and effective product manufacturing. This process involves melting a metal and forcing it to pass through cavities or chambers at high pressure and then allowed to cool. After the metal cools, it takes up the shape of the die cast. This method reduces time and effort required in manufacturing a number of products. Though a number of non-ferrous materials are used in die casting, aluminium is generally preferred in a range of applications.

There are many benefits of using aluminium die castings. First, this metal is lightweight and is highly corrosion resistant, which makes it suitable for use in a variety of applications. Moreover aluminium is strong, stiff, hard and has a high strength to wait ratio. All the features make it highly suitable for use in automobile part manufacturing. Its high thermal and electrical conductivity make aluminium a great choice for telecom and computing industries. These attributes also make this metal perfect for use in electrical housings and connectors. Above all, aluminium has good EMI and RFI shielding properties, so it is suitable for use in the manufacture of handheld devices. Plus, aluminium retains its strength even at very high temperatures. So, even if it is melted and then cooled, it will not lose its original attributes. All these features make this metal perfect for die casting.

There are basically two methods used for die casting - hot chamber or cold chamber. While die casting aluminium, the cold chamber method is preferred over the hot chamber method as aluminium may react with iron when it is heated to a very high temperature. In the high pressure aluminium die casting, a separate chamber is used to melt the metal. When the metal alloy reaches the molten stage, the required amount is slowly transferred into the cold chamber, and into the hydraulic piston. Using this technique, high number of casts with high-quality casts can be produced over time. Different types of aluminium alloys are used in various manufacturing processes. The most commonly used alloys are A380, 413 and 383.

High pressure aluminium die casting is a versatile technique that is not only efficient, but also allows manufacturers to design and create high-quality durable die casts. 

Aluminium Alloy Vs Magnesium Alloy Die Casting

Die casting is a process in which molten metal is forced into a chamber at very high pressure. When the metal cools, it forms the shape of the mould. In order to prevent any type of reaction, the cast is made of non-ferrous metals such as steel, copper, aluminium, zinc, magnesium and their alloys. This metal casting process is relatively simple and doesn’t need a large investment. 

Both magnesium and aluminium alloy are used for die casting process. Both have their own advantages and disadvantages.


Melting Point

The melting point of the metal is the first point of comparison between the two alloys. Magnesium has a melting point of 1800 LB while aluminium has 2500 LB. As aluminium alloy has a lower melting point than magnesium alloy, it will make an economical choice. Again the choice of alloy depends on the type of furnace and melting pot.


Melt Loss

Another point of difference between the two alloys is the melt loss, which depends on the type of die casting technique used. Generally during magnesium casting, melt loss of 5 to 25% is seen while aluminium has less melt loss of 5 to 10%.


Cost

Another point that is generally taken into consideration while choosing either of the two alloys is the cost of production. Magnesium has a quick solidification rate, so, it doesn’t need high pressure like aluminium to be solidified. In many ways, it can be seen that magnesium alloy is more economical than aluminium die casting.


Machinability

While comparing the machines used to die cast both alloys, it is seen that magnesium is advantageous over aluminium. Magnesium machines have natural lubricity and quickly dissipate heat, which enables carving deep cuts without damaging the surface finish. Plus, more magnesium castings can be made as the die caster has a high tolerance to this metal than to aluminium alloy. When you compare the lifespan of carbide tools used to machine magnesium and aluminium, you will see that they last up to 10 times longer when used with magnesium.


Applications


Generally aluminium is used in die casting of automotive parts such as clutch pedal and support bracket. If the die caster is using a hot chamber die casting machine, then magnesium die casting requires 160 metric ton. For, aluminium die casting, it will require a 550-650 metric ton cold chamber die casting machine to do the same. Here, if you compare the price with the machine size required, then magnesium alloy becomes a more affordable option.

Precision Casting Provides You the Easiest Way to Maintain Accuracy and Quality

The use of metals in today’s world is much more than one can expect. Almost each and every industry requires metals in some form or the other. Manufacturing industries use metals as raw materials in the production of different types of goods. Simple instruments, kitchen equipment, machinery, electronic goods and items, scientific instruments and equipment, furniture, decorative items, and all such types of goods use metals as major raw materials. Manufacture of metals uses different processes based on the requirement. Precision casting is the one of the most commonly used process for the manufacture of metals. Several industries use this form because of the advantages it has got over all the other processes.

A precision die cast metal is considered to be superior over all others. This is because of all the advantages it has got:

• Weight
The products made using this process are much lighter in weight than the metal parts made with all other kinds of processes.

• Simpler Assembly
Coring holes and tapping them to drill sizes are made possible. It is possible to cast internal and external threads.

• Multiple Finishing Techniques
The surfaces of the casts can be made smooth and textured. It is also possible to plate them easily and create multiple finishes. Very little surface preparation is required to make this possible.

• Strength
The products made using precision casting are much stronger than those of same dimensions made with all other processes, including the plastic injection techniques. The walls are thinner, and they are much stronger.

• Stability
As far as die cast products are concerned, stability is a very important factor. These products are dimensionally stable and highly durable. They are also resistant to heat.

• Accuracy
All the elements using the process maintain close tolerances. They are highly accurate.

• Production Rate
It is possible to make complex shapes that have high tolerances. The tolerance achieved using this process is much higher than that achieved with any other mass production process. Very little or no machining is required for this process. A large number of identical castings can be produced easily.

A precision die cast process can produce parts with different alloys and elements. Zinc, aluminum and magnesium are the most commonly used. Good quality metal parts with high accuracy can be produced easily, and that is why it is commonly used by most manufacturing industries. You could also use the process to make metals parts of the best quality for all your purposes.