The Choice of casting metal is essential in the metal casting process, as the metal properties directly determine the product characteristics, especially for products used in Harsh environments; in addition, different casting metals significantly impact the cost of the final product due to machinability, material cost, etc.
This blog will discuss the importance of die-casting and highlight all the casting metals primarily used for die-casting or metal-casting processes.
What is Metal Casting – An Overview
Metals casting is a process that helps industrialists create new shapes and sizes from metals. It involves pouring molten metal under high pressure into the mold cavity, which contains chambers machined into different shapes. Pouring the molten metal into the mold gives it a new shape per industry specifications.
Casting Metal
Die casting is integral for casting metals to produce highly specialized items. This process involves high pressure that ensures the molten metal takes a new shape. Die casting allows manufacturers to create metal parts that are accurate and usable for different industries. The process ends with ejecting the newly formed metal from the mold, after which polishing occurs to smooth surfaces.
Related To: What is Die Casting: Die Casting Process and Overview
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The most commonly used Casting Metal
The industry uses many metals for the process of die casting. Some of the prominent ones are zinc, aluminum, and magnesium. But these are not limited, as several other options like copper, lead, brass, and tin, are available for specific projects.
Each metal offers different characteristics and reacts uniquely to conditions like temperatures, pressure, and type of mold. Some metals provide relatively faster metal casting with a simple, fast, and stable consistency. Let’s explore a variety of widely used metals in this process.
Aluminum
Aluminum casting products
Aluminum is a primary choice of casting metal, Widely adopted in different industries, including automotive, construction, and energy. Here are some key features of aluminum that make it the primary choice for die-casting:
- A reasonably lightweight metal, Aluminum is the most popular and essential material for die casting due to its high strength and temperature resistance.
- It simplifies the manufacturing process while enhancing efficiency and provides versatility in achieving desired surface finish characteristics.
- Aluminum is optimal for producing parts in industries such as technology, energy, automotive, aerospace, and consumer electronics products due to its excellent thermal and electrical conductivity
- The most commonly employed aluminum alloys for casting are A356, A360, A380, and A383.
- Aluminum is also used in the telecom industry. Its ability to disperse heat makes it an ideal material for RF fitter boxes.
- Aluminum is highly suitable for casting extremely complicated shapes.
Magnesium
Magnesium Die-Cast Product
Magnesium is another popular casting metal for manufacturers. It has high stiffness and castable properties. Moreover, it has a superior ability to meet tight tolerance requirements up to ±0.005 mm. Here are some peculiar properties of magnesium for casting applications:
- Mg is a great alloy that can be machined faster than aluminum
- It is a low-density alloy and provides ease of machining.
- It gives a lot of benefits, such as easy pouring, good fluidity, and a smooth finish.
- Magnesium’s high EMI and RFI shielding properties make it ideal for electronic and medical equipment use.
- Unlike steel, it is 75% lighter in weight and has excellent mechanical strength, making it ideal for complex net shapes and casting applications.
Zinc
Zinc is a widely used casting metal in various industries for die casting due to its versatility and precision compared to other metals.
- Zinc is probably the most convenient alloy for die casting.
- Its low melting point makes it easy to work with while maintaining high strength and quality finish.
- Additionally, zinc is considered the most economical alloy for die casting thanks to its fluidity, excellent strength, and smooth finish, which all contribute to its aesthetic appeal.
- Moreover, zinc also offers good electrical and thermal conductivity making it a practical, and efficient option for die-casting applications.
- Zinc is a versatile material that can be easily molded into intricate shapes, and structures, making it ideal for a wide range of uses.
- Zinc die-cast products are used in the manufacturing of cars, and medical devices.
Copper
Copper Investment Cast Product
When it comes to non-standard complex components, copper can be a good option. Engineers can die-cast metals using copper at high pressures. However, casting copper in pure form is challenging. This is why different copper alloys are preferred for die casting.
- Copper alloys are manufactured by first melting the alloying material then melted copper is added to it. The molten mixture is then cast, cooled, and solidified.
- Copper offers many outstanding advantages: high hardness; excellent water resistance; high corrosion resistance; highest mechanical properties of alloy die cast; excellent wear resistance, excellent dimensional stability, and strength approaching that of steel parts.
- The two most common copper alloys are Brass (alloyed with zinc) and bronze (alloyed with tin). Brass is typically more widely used.
- It is used for plumbing fixtures, musical instruments, and decorative items.
Brass
Brass is a decent option for die-casting metals. Brass die casting produces repeatable products in complex shapes, which are repeatable for different products.
- Brass; An alloy made up of zinc and copper.
- Great for conducting electricity yet spark resistant.
- It has fair dimensional accuracy and excellent resistance to corrosion.
- Brass offers numerous finishing options like chrome plating and mechanical finishing with polishing and buffering.
Lead
Lead is a key metal that has a decent reputation in the manufacturing industry. It is key for the metalworking process and helps in the formation of a wide range of products. This is where lead shines, resulting in the production of high-quality products through die-casting.
- Lead components play a crucial role in the production of automotive battery parts, especially terminals.
- Lead alloys have a high density of 11.34 g/cm3 and are capable of producing parts that have very close dimensions.
- Lead alloys are used in applications requiring special forms of corrosion resistance.
- Such as in the food services industry for public health issues.
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Things To Consider When Selecting Casting Metals For Your Project
When it comes to the die-casting process, selecting the suitable casting metal is crucial for creating durable products. If the chosen metal doesn’t meet the criteria of the end product, it can pose challenges. To make the selection process easier, here are some essential factors to consider;
Die-casting mold & ejected part
- Strength: Different metals have varying levels of tensile strength, which determines how much force they can withstand before breaking. Engineers choose metals with specific strengths based on the requirements of their projects.
- Ductility: Ductility is another essential factor to consider, as it affects how easily the metal can be shaped during manufacturing. Less ductile metals are not good for reshaping smaller products.
- Machinability: When talking about machinability, we are referring to how easy it is to cut a metal according to specified requirements. This characteristic can vary depending on the type of metal being used for casting application. If a metal with poor machinability is chosen, it may necessitate the use of more sophisticated equipment for cutting, leading to higher costs.
- Weldability: When it comes to manufacturing, welding is often the best choice. However, selecting a metal with poor weldability can complicate the production process, potentially leading to delays, and increased costs of the project.
- Cost: The casting process usually provides economic benefits, when used for producing parts in large volumes. But, it’s important to understand the tooling costs for casting. Because it can lead to increased costs for tools in the beginning.
Casting Metals Comparison Chart
Each type of metal has its unique characteristics that set it apart from the rest. Let’s take a look at these metals in terms of how easily they can be shaped, how well they can stretch without breaking, their ability to resist rusting, and other factors:
Table: Casting Metals Comparison Chart
| Casting Metals | Malleability | Ductility | Corrosion Resistance | Costs | Machinability | Weldability |
| Aluminum | High | Excellent | Good | Low | Good | Excellent |
| Steel | Low | Low | Low | Medium | Good | Good |
| Cast Iron | Medium | Medium | Low | Low | Medium | Good |
| Copper | High | High | Excellent | High | Good | Good |
| Zinc | High | Medium | Good | Low | Good | Good |
| Brass | Medium | Medium | Excellent | Medium | Good | Good |
Why Choose Prolean For Your Metal Die Casting Projects?
With years of experience in die casting, Pro-Lean can be your go-to choice for metal casting projects. We provide the metal casting solutions that take your prototypes to the next level. With access to a wide range of materials for die casting such as copper, titanium, alloy steel stainless steel, we ensure that your project achieves the success it deserves.
Pro-lean helps you achieve precision and accuracy with the least waste in short cycles, from laser cutting of metals to CNC machining. Contact us for a complete walkthrough on how Pro-lean will ensure success for your specific metal casting project. Send us your queries to get an instant quote!
Read more:
- How To Choose the Best Copper Die Casting Manufacturer
- Low-Pressure Die Casting: A Simple GuideHigh Pressure Die Casting: An Overview
- High-Pressure Die Casting: An Overview
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Summing Up
The die-casting process is an industrial practice that creates different types of metallic products. These products are in different shapes and sizes that many sectors consume worldwide. It utilizes different metals, depending on the industry and type of product requirements.
Die casting allows for the effective utilization of metals, helping manufacturers achieve efficiency. With the advancement of technology, many new alloys will come into play, further enhancing the potential of die-casting metals. This will help die casting manufacturers to improve their products as well as create new ones.
FAQs
Q1. What are the two types of die casting?
There are two widely used processes of die casting; hot-chamber die casting, and cold-chamber die casting which are practiced in the industry.
Q2. Why is it called a die-cast?
The word “die” refers to a tool that helps engineers cast metals. Other castings are different from die casting. These are investment casting and sand casting.
Q3. Which metals are used in Die casting?
Various types of metals can help cast new products. These include aluminum, copper, zinc, steel, brass, and magnesium. Each metal has its characteristics and nature for casting.
Q4. Which metal is easiest to cast?
Zinc, due to its low melting point of 425 degrees Celsius known to be the easiest metal to cast. It usually takes minimal time to melt and cool.
Q5. What is the difference between die casting and investment casting?
Die casting involves injecting molten metal, into a steel mold cavity under high pressure. The molten metal fills the mold cavity, solidifies, and the part is ejected from the mold. On the other hand, investment casting is employed in industries based on low-wax casting.
Resource
K.G. Swift, J.D. (2014), Casting Process: Second Edition Product development: Manufacturing Process Selection Handbook, Retrieved From Science Direct
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