Die Casting is a high volume casting process used to make a variety of metal parts used

in a wide range of products and industries.

The process uses steel molds that are injected at high pressure with molten metal to
form the part. The steel molds are made to a high level of precision ensuring that the
finish and tolerance is very good.
In the Cold Chamber casting process, the molten metal is ladled, sometimes by hand,
from a molten crucible of metal into an actuator mechanism that then forces the molten
metal into a mold under high pressure provided by a hydraulic piston.

“Cold chamber die casting, also known as cold casting, is the die-casting process that
involves melting metal in a separate furnace and pouring the molten metal into an
unheated chamber for injection into the mold under high pressure. It is best for metals
with higher melting temperatures, like magnesium, aluminum, and copper. Like in hot
chamber die casting, a cover gas is used to protect the molten magnesium and prevent
oxides from forming in the casted part. Cold chamber die casting is the more cost-
effective type of die casting since it requires less maintenance. However, cycle times
with cold chamber die casting are longer, and product quality may be lower than that of
hot chamber die casting. This is because the high pressure used in cold chamber casting
can lead to an inability to vacate gases before the solidification process. ”
https://www.xometry.com/capabilities/die-casting-services/magnesium-die-
casting/#:~:text=Hot%20chamber%20die%20casting%20is,for%20hot%20chamber%
20die%20casting.
The hot chamber process is similar, but the hydraulic cylinder is submerged into the
molten metal. This allows for better process control and faster cycling times. Only
metals with low melting points can be used in the process as the corrosive nature of
molten aluminum and other higher temperature melting point materials will
prematurely shorten the life span of the actuator.
Die casting tools are complex pieces of equipment. They have to be large and
withstand tons of pressure while the molten metal is being injected with hydraulic
pressure. The molds have a stationary part which is typically the cavity and forms the
outside of the final part. The core forms the inside of the part. Once the part has been
molded the mold opens with the part sticking to the core. Subsequently the part is
kicked off the core by a set of ejector pins that sit on a backing plate that moves.

The molten metal is injected first through a Sprue and the through runners and into the
part through numerous gates. This process is closely analogous to injection molding of
plastics. Entrapped air is ventilated through small tiny vent openings.

The complexity of these molds makes them very expensive and with long lead times to
produce the molds. Designs are therefore often proven with metal prototypes and often
with simpler expendable mold casting processes first or CNC machining.
Material is fed through a Sprue and then into a runner system, optimized to provide
steady flow of molten metal. The material is then fed into critical feed areas of the mold
through the numerous gates. As the cavities fill, air is pushed out and eventually molten
metal fills small areas around the exit points.

When the part is ejected from the mold a lot of metal remains that needs to be
discarded. All of the above areas (sprue, runner etc) solidify as well and need to be
trimmed off afterwards. Luckily all these metals can be recycled, and the discards are
therefore reused.
Most die castings are made from Zink or Aluminum. Magnesium is also used where
weight has to be kept to a minimum. All these metals have very good strength and
durability. Material choices
Since undercuts are not accommodated through simple Core Cavity (2 part) molds,
these can only be done through some form of insert that either comes out with each
part, or that is removed automatically before the tool opens.

In sand casting this is accommodated through a ”removable core” of sand. In die casting
such an approach does work, but it would be made from metal. This does however
drastically slow down the production rate as the core needs to be removed by an
operator at the machine.

Instead, the tools have built in “sliders” that move out of the molded part, before the
tool opens.

In the above figure, a plumbing fixture is being molded. The sliders will create the
openings for the fixture. There is still some final machining to open the cavities inside.
Can you picture what the final part will look like and why it needs additional machining?
There are many die casting alloys of Zink, Aluminum and Magnesium. The exact
application may require further investigation and research with the die caster, but the
above materials are the alloys that are generally used for most product design
applications.

Looking at the above table you can see that A380 has the highest tensile strength of the
3 materials, but it will however also start to stretch more easily than Zamak 3 (Zink) as it
has a lower Yield Strength. Zink is therefore stiffer although still very strong. Impact
strength is the ability of a material to withstand cracking or breaking when hit hard. The
higher the number the stronger it is. This is why zink for example is good in applications
where there is a lot of vibration and intermittent loading.

From the table one can see that Magnesium has no performance properties over the
other 2 materials. This is however only partly true because the material is much lighter
and hence the weight to strength ratio is higher.
The bigger the part, the bigger the machine. Tesla is making some of the world’s biggest
die cast parts using the “Giga Press’. It produces about 1.2 million pounds of force.
Due to the amortization cost of the tooling, it takes a long time for the break even point
to be reached, where the investment starts to pay off. The break even point is
eventually surpassed and the cost per part becomes less expensive as a certain
production quantity is reached.
Zinc:
The traditional metal for Die Casting is Zinc. It is a strong and durable metal and is the
material typically used in Hot-Chamber die casting as a rule. The melting temperature
of Zink is about 420 degree C, which is low. This means that it uses less energy as a
process and in addition the lower processing temperature, puts less wear on the
tooling.

The cast base for the saw illustrates how zinc makes strong small parts that are suitable
for tool manufacturing. The cell tower base shows how die cast zinc is a an extremely
tough and durable material that also has superior corrosion resistance to other materials
when used outside. In both of these applications, weight is not a negative consequence.
Aluminum:
Aluminum is generally used in engine blocks and other higher temperature machine
applications. Also because of the lower weight it is often used in consumer products
and increasingly in transportation in order to increase the range of electric vehicles.

Aluminum castings can also be finished to a high cosmetic level as shown in the
examples above. The Parrot headphone headband would never be strong enough as
shown if made in plastic.
Magnesium is used where material weight has to be minimized, as it is a strong and
durable metal with a low molecular weight and density. It is generally Cold-Chamber
die cast but can be Hot Chamber die cast as well.

The drone is a great example of incorporation of a die cast magnesium part to mount
the camera. The magnesium provides the strength of metal, but with a very low weight.
The design of cast parts is critical to creating good dependable cast parts. Certain rules
and guidelines have been developed by the industry that should be followed. It is also
advisable to have the final design reviewed by the manufacturer early so that feedback
can be provided by the experts. In addition, different molders have different
preferences, and it is important to listen to those as they will improve part quality and
lower cost and lead times.

In the design of cast metal parts the following rules apply in most instances to both
expendable and permanent mold applications.
The parting line is something that needs to be decided on by the industrial designer and
engineers in consultation with the manufacturer. The parting line affects how the mold
is constructed and also how draft angles are implemented.
Parts are not always flat. This means that the parting line moves and is referred to as a
stepped and sometimes curved parting line.

The surface that is on the parting line is the Parting Line Surface
These circular cast rings share an overall diameter dimension. The draft has been
exaggerated to show how different the parts will look based on the parting line and
draft. Since the parts must taper from the parting line (draft), the wall thickness changes
except for the example 3.
These circular parts are similar in that they are cast circular rings. The draft has been
exaggerated in order to show how different the core and cavity would be in each
situation. The core and cavity are shown on the right of each part.
The design of cast parts is critical to creating good dependable cast parts. Certain rules
and guidelines have been developed by the industry that should be followed. It is also
advisable to have the final design reviewed by the manufacturer early so that feedback
can be provided by the experts. In addition, different molders have different
preferences, and it is important to listen to those as they will improve part quality and
lower cost and lead times.

In the design of cast metal parts the following rules apply in most instances to both
expendable and permanent mold applications.
The wall thickness of cast parts should ideally be uniform. Otherwise, the part may
distort and and possibly create voids. The exception is for the ribs that strengthen the
part as they should be thinner, otherwise they will create thicker sections where the join
the outside wall of the part, creating sink marks below.

When machining parts out of solid stock this does not apply. This is why the part
shown on the left can be left as is, whereas the part on the right represents how a
casting should be designed in order to reduce problems in production and to also use
less material.
Bosses are used for a variety of reasons. They can be used to mount Printed Circuit
boards in electronic applications. They can be used to screw to 2 housings together or
mount motors and other functional parts.

The part on the left is used as a support base for a product and rather than be cast as a
solid piece of metal, the underside is cored out and then strengthened with ribs. The
product looks solid from the top but will be lighter but strong and costs a lot less to
manufacture.

The part on the right is a housing for a street light LED housing. The thermal properties
of the Zink die casting make die casting a good choice. The cast in ribs add both
strength and heat dissipation. The Zinc is corrosion resistant as well and as such is an
even better choice than aluminum for this application.
Bosses should be round and ideally connected to the side walls with thinner ribs that
provide strength and material flow during the casting process.

The example showing the square bosses is going to create problems during the casting
process. There will be sink marks on the outside walls when the material solidifies and
shrinks, given the extra thermal mass of the cross section. This is undesirable both from
a functional and visual perspective. The sharp corners will further create areas where
the material is prone to breaking since sharp corners act as stress risers.

Adding radii (fillets) on inside corners removes stress concentrations and in turns
strengthens the part. It also aids in filling the mold and prevents dirt from accumulating
in these corners.
The effect of draft can mean that the walls of the part get thinner as shown due to the
tapering of the side walls. An alternative would be to move the parting line as shown. In
that case the draft on the cavity is in the opposite direction of the draft on the core and
the wall can maintain constant. This design is however not better unless the thinning of
the wall becomes excessive. A gradual change in wall thickness does not cause
problems with sink marks.
When designing die cast parts in particular, it is important to consider the high cost of
tooling. Certain aspects of the tool design are predictable such as the shrink of the part
when molded. When it comes to fine details and tolerances however, on can rely on for
example making the fit tighter between the parts, by first making it looser. Removing a
little bit of material from the mold will in turn allow for a slightly enlarged part and
tighter fit. In contrast, if the fit is too tight, then material either needs to be welded back
in the tool or each part needs to be machined for a closer fit.
The ejector pins put enough pressure on the warm part while ejecting it from the mold
that they leave visible surface mark detents on the surface. It is something that needs to
be decided on with the designer. Sometimes I have put notes on my technical drawings
saying that “ejector pin marks in consultation with client”.
Cast parts usually entrap a certain amount of gas that forms out of the molten metal as
it it cools and solidifies. The porous nature of a casting can be a severe problem or just a
matter of process.

The outside surface is the least likely to have porosity as it is solidified first and
effectively creates a skin. Machining the casting is likely to expose some porosity in the
material. Whereas machining may be necessary to create a feature such as a thread or
hold a tolerance, the porosity may at that point become a problem or not depending on
the application.

Keeping wall thicknesses constant and adding fillets helps reduce the probability of
larger gas bubbles forming that could more severely impact the casting strength.
Vacuum Impregnation: is a process that seals porosity, creating watertight
components. It is also used after machining to seal the open inside surface exposed
in the machining operation.
A wide variety of metal parts are painted with liquid paints. Whereas paints have a
range of enviornmental and health concerns they are used mainly for their versatility,
wide range of colour choices and finish choices. They range fro flat to gloss finishes and
they can even be painted with texture through additives or technique. Sometimes a
metal part such as a casting or sheet metal part has to be matched exactly in color to a
plastic part. This may necessitate paint.

There are specific paints used in the industrial sector that are more suitable for
industrial production. Paint can be water based or solvent based. Solvent based paints
outgas Volatile Organic Compounds VOC’s that pose health hazards. Furthermore,
given the larger scales of use in industry, these are often avoided. Sherwin Williams is a
large supplier of industrial paints. They produce water based and low VOC paints such
as Polane Poyurethane Enamels. These are often 2 part based to promote quick curing.

In the automotive industry water-based enamels are the preferred choice with
clearcoat in order to protect the paint finish and control the lustre.
Powder coating is a durable and common coating found on all kinds of products
including bike racks, electronic products, barbeques, fences etc. Powder coating
protects the roughest, toughest machinery as well as the household items,

The powder coating is a thick coating of powdered plastic that is electrostatically

applied to product and then melted with heat in an oven where it is cured to form a
thick and unform layer that can even hide surface blemishes and scratches.

Powder paints are available in a wide variety of textures, gloss levels, and colours.
Materials include: epoxy, hybrid, urethane and polyester.

The powder coating process itself offers another advantage – it is environmentally

friendly, and virtually pollution-free (virtually no emissions, no solvents, and no
hazardous wastes). The company RLD in Ottawa for example has a “complete recovery
system in use, to ensure little or no waste of the powder coating material.”
Plating produces some very attractive and durable finishes such as Chrome finishes.
The plating process is used for a very large number of products and can either be
aesthetic or functional.

It is used in a large number of industries including: Plumbing, Automotive, Jewelry,

electronics
Plating produces some very attractive and durable finishes such as Chrome finishes.
The issue is the amount of chemicals and the type of chemicals used and how they
affect workers as well as how these chemical are introduced into the atmosphere.

“Activities at electroplating shops include surface preparation, surface treatment, and

post-plating treatment, all of which may release pollutants into the air and may
contribute to health concerns in the shop and in the community.
The best electroplating shops implement pollution prevention strategies not only to
comply with federal, state, local, and Tribal laws but also to further minimize impacts
on human health and the environment. Check with your state, local, and Tribal”

https://www.epa.gov/sites/default/files/2017-
06/documents/electroplating_comm_info.pdf
gencies for existing regulations.
Anodizing is usually used with aluminum machined and cast parts to both improve
the resistance to corrosion and provide a surface that does not mar as easily and has
a brighter and cleaner finish. It is a passivation process, which means it becomes
"passive", that is, less readily affected or corroded by the environment.

The process is called anodizing because the part to be treated forms

the anode electrode of an electrolytic cell. Anodized aluminum accepts paints much
better and is used in all kinds of architectural prefinished extrusions. The appearance
of a shiny color dyed surface is often a clear indicator that the part was anodized.

According to the Aluminum Anodizers Council “Anodizing is a water-based process

and uses no VOCs. There are no vehicle solvents, no carrier resins, and any
pigmentation used in anodizing is created by extremely small amounts of metals or
dye securely locked within the hard surface. No halogenated hydrocarbons or similar
toxic organics are used in anodizing.”
PVD (physical vapor deposition) coating, also known as thin-film coating, is a process
in which a solid material is vaporized in a vacuum and deposited onto the surface of a
part. These coatings are not simply metal layers though. Instead, compound materials
are deposited atom by atom, forming a thin, bonded, metal or metal-ceramic
surface layer that greatly improves the appearance, durability, and/or function of a
part or product.
Drawing is when a sheet metal blank drawn into a forming die by the mechanical
action of a punch.[1] It is thus a shape transformation process with material retention.
The process is considered "deep" drawing when the depth of the drawn part exceeds
its diameter. This is achieved by redrawing the part through a series of dies.
The active draw area is confined to the entry of the die, as th metal changes direction
into the die and is stretched. Once the metal has been pulled in , it effectively stops
stretching inside the tool. In order to make deep drawn parts, they are often drawn in
successive dies. The first die will have a larger opening and shaller pull. This is followed
by successive dies with successively smaller die openings. This in essence allows the
shape to go through some re-orientation and pre-stretching.
Stamping is a form of deep drawing in that it requires tooling that is drawing the a
sheet metal blank into a part. Stamped parts are the mainstay of manufacturing
automotive exterior parts. Stamping presses are huge presses that use enormous
pressure to tightly stamp the parts into shape. The stamped parts usually need some
trimming to size and edge treatments after stamping.
Spinning is a process that uses a lathe and pushes a round piece of flat metal against
a form with a roller lever. The process is very applicable to certain complex round
shapes and prominent in industries such as lighting fixtures.

Sometimes the method is used to prototype more complex methods such as deep
drawing or for smaller volume production of very large cooking pots for restaurants.

The tools may be made from wood or metal. The mold is known as a mandrel. The
raw stock is a round disc of metal (usually aluminum) and is known as a blank. The
tail stock keep the blank in place securely during the forming operation.

This can be a manual method, which requires a trained and skilled operator and
considerable strength. The other approach is to automate the process with a CNC
approach. In this case the output is greatly scaled in terms of production and the
process becomes much more viable in terms of cost.
Spinning is a process that uses a lathe and pushes a round piece of flat metal against
a form with a roller lever. The process is very applicable to certain complex round
shapes and prominent in industries such as lighting fixtures.

Sometimes the method is used to prototype more complex methods such as deep
drawing or for smaller volume production of very large cooking pots for restaurants.

The tools may be made from wood or metal.

Slide forming allows very complex small parts (often for electronics industry) to be
formed. The process uses a coil of metal that is fed through the Slide forming press.
As the strip of metal advances through the punches it receives a series of subsequent
operations. The final part that emerges has gone through a series of operations. The
speed of this process is very high allowing such small and complex items to be
produced at a very low cost.
Parts made from metal wire are very common in designed products. They can be
used as handles or connectors or springs. These parts are produced rapidly in a
variety of metal materials utilizing CNC programmed wire bending machines that can
bend a wire in many different shapes quickly and accurately.