Casting Metals: Most Commonly Used Casting Metals for Manufacturing New Products

“The process of fabricating metals to manufacture products of different shapes and specifications is referred to as die casting. Engineers in the industry use different metals for this process.” 

Metal casting is a reliable manufacturing method used to create metal components in various industries. It is a commonly used process for shaping various products and has revolutionized the industry significantly.

The quality of products made through die casting, like other fabrication methods, relies on the metal used in the process. The choice of metal impacts the appearance, strength, reliability, and overall quality of the final product. For casting metals into new shapes and forms, die-casting is necessary and entails the formation of specialized products. 

This blog will discuss the importance of die-casting. It will highlight all the key metals that are primarily used for die-casting or metal-casting processes. 

What is Metal Casting – An Overview

Casting Metals is the process that helps industrialists create new shapes and sizes from metals. It is a practice in which molten metal is put under high pressure into the mold cavity. This cavity contains chambers machined into different shapes. Pouring the molten metal into the mold gives it a new shape as per the industry specifications. 

Metal casting 

Die casting is integral for casting metals for the production of 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 make surfaces smooth. 

Related To: What is Die Casting: Die Casting Process and Overview

Most Commonly Employed Metals For Casting

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 in the market for specific projects. 

Each metal offers different characteristics and has a unique reaction to conditions like temperatures, pressure, and type of mold. Some metals provide a 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 for most metal casting operations due to its compatible nature. Different industries including automotive, construction, and energy. Here are some key features of aluminum that make it the primary choice for die-casting:  

• A fairly lightweight metal; Aluminum is the most popular and important 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.
• The telecom industry uses aluminum as well. 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 metal for manufacturers when it comes to die casting. It has high stiffness and castable properties. Moreover, it has 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 smooth finish.
• Magnesium’s high EMI and RFI shielding properties make it ideal for use in electronic, and medical equipment.
• Contrary to steel, it is 75% lighter in weight and has great mechanical strength which makes it ideal for complex net shapes and casting applications. 

Zinc

Zinc is widely used 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 applied more widely.
• It is used for plumbing fixtures, musical instruments, and decorative items.

Brass

Brass is an alloy of zinc which is a decent option for die-casting metals. In fact, brass die casting produces repeatable products in complex shapes and the process is 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.

Things To Consider When Selecting Metals For Your Die Casting Project

When it comes to the die-casting process, selecting the right 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 important 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 important factor to consider, as it affects how easily the metal can be shaped during the manufacturing process. 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 own 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

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. 

Die casting service

From laser cutting of metals to CNC machining, Pro-lean helps you achieve precision and accuracy with the least waste in short cycles. Contact us to get 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

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 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