Die Casting Manufacturing
Most die cast parts are specified as replacements for machined parts or other casting methods, typically achieving significant cost savings through reduction of manufacturing processes and lead time. The machining process of die-cast parts must be considered well before any order for the tooling is released. A careful evaluation of machined requirements can lead to redesign for net shape die-casting or near-net shape with reduced number of secondary operations.
Die Casting - What is it?
The basic die casting process consists of injecting molten metal under high pressure into a steel mold called a die. A complete die casting cycle can vary from less than a few seconds for small components to 2-3 minutes for a casting of over 30 lbs, making die casting the fastest technique available for producing precise non-ferrous metal parts.
Die casting can be produced in nearly every conceivable size and shape. It provides the freedom to design intricate configurations that meets the functional requirement of the component. The die casting process produces castings with very close tolerances, often eliminating the need for finished machining operation.
Die Casting - Aluminum
Aluminum alloys have been proven ideal for a wide range of products because of the unique combination of qualities they possess: light weight, good corrosion resistance, high tensile strength, high dimensional stability, high thermal and electrical conductivity. Alloy 380.0 is the most commonly used Aluminum alloy for die casting, and has been found to meet customers' various needs. Importantly, SKS can also cast Aluminum Alloys 360, 390 and 413.
Die Casting - Zinc
In general, the mechanical properties of zinc alloy die castings at normal temperatures are superior to sand castings of grey iron, brass, and aluminum, particularly in toughness and impact strength. They are much stronger, tougher, and more dimensionally stable than injection molded plastics. The reduced cost and improved properties has made it an ideal replacement for iron, copper, aluminum alloys or plastics parts.
SKS can cast Zamak #2, #3, #5, #7, ZA8 and ZA27. Zamak is characterized by excellent retention of impact strength and long-term dimensional stability. It has been used for decades in a multitude of engineering applications with excellent performance results.
Description of component: BODY PUMP
Function: oil pumping station, air & gas filtration pump. Each component is required to meet pressure test of over 5,000 psi without resulting in damage to the component assembly.
Die cast machined component weighs: 2 lb. 14 oz.
Original component: machined sand casting
Rejection rate: 20%
Production rate: 5 – 7 pcs per shift
Die casting component:
Reject rate: <1%
Weight reduction 5%
Production rate: 250 pcs per shift
Cost Reduction: over 50%.
Component description: Home security lockbox
Original component raw material: steel tubing
Manufacturing processes includes: bending, welding, machining, painting. The original manufacturing process is virtually a custom made-to-fit component.
Die casting component raw material: zinc.
Die casting process virtually eliminates the variability of both critical and functional features of the component. The reduction in cost and lead time is dramatic.
Cost Reduction is over 50%.