A casting technique must be chosen based on a combination of design requirements and cost. As the casting method effects the yields, the design of the part and the secondary finishing procedures, it is frequently a process that is iterated. In order to streamline the process and eliminate confusion, it is necessary to become familiar with the advantages of each method.
Die casting, permanent mold casting, and sand casting are the primary processes for creating aluminum parts with a near-net shape. These final two are frequently muddled or misconstrued. Die casting and permanent mold casting will be contrasted in this section, and the merits of both will be discussed. You may also want to Make the Most of Your Die Casting Mold to the Fullest Extent.
DIE CASTING vs. MOLD CASTING
As the molten aluminum cools, steel molds create a chamber that is used in both the permanent mold and the die casting process. A unique hollow is created in sand every time, making the techniques distinct from sand casting. To prevent metal abrasion, die coating is applied to the steel.
The main difference between the two steel die processes is how the metal enters into the tooling. As the metal cools and hardens, it pours out of the mold into the hollow. Turbulence can be reduced by using a gate to regulate flow speed. In most cases, the die is intended to fill from the bottom or side, with the riser at the highest point.
Molds are filled, and the metal is allowed to harden before the mold is opened and the part is extracted. To build interior galleries, inserts must be inserted before the mold is closed.
With die casting, metal is pressed into the cavity under pressure, as opposed to gravity-fed permanent mold casting. As a result, it has a lot in common with plastic injection molding. As with permanent mold casting, the mold is opened and the cast forms are removed once the metal has solidified.
ADVANTAGES OF DIE CAST WORK
The as-cast surface has a greater than 125 microinches of surface polish. Secondary machining and finishing may not be necessary.
High geometric accuracy, even with tiny walls, is possible.
Lower unit prices on longer runs due to a faster procedure than permanent mold casting.
A lot of the time, equipment can be used in a smaller area than a permanent mold casting process. Higher priority for the caster than the customer, but may reduce overhead costs provided on the basis of floor space used by the caster
MOLD CASTING ADVANTAGES IN THE LONG RUN
Permanent mold dies are typically less complicated and hence less expensive than die casting dies.
Surface polish is typically between 125 and 300 microinches, which means that further machining is not necessarily necessary.
Because it creates less porosity than die casting, the process has a higher yield for completed parts.
They are more durable.
LOOK AT VOLUME AND PART CHARACTERISTICS
Permanent molds and die casting are more cost-effective when you need big volumes. For a higher price, die casting tools are more precise and have smaller walls and smoother surfaces than permanent die tools.
Die casting is quicker, but permanent molds require fewer tools and are therefore less expensive. As a result, the parts are stronger and less prone to porosity.
