Time to read: 7 min

Die casting is a manufacturing process in which molten metal, typically a non-ferrous alloy like aluminum or zinc, is injected into a mold or die to create precise and complex metal parts. It’s a method known for its efficiency in producing large quantities of parts with high precision. The figure below shows a magnesium die-cast automotive component:

This article looks at what die casting is and how it works. 

Die Casting Mold Overview

Die casting works by injecting molten metal into a die or mold. Mold design and manufacturing are crucial elements of the die-casting process. The mold cavity is created using two hardened/tempered steel or cast-iron dies machined to the desired part’s net shape. Pressure die casting involves injecting molten metal into the die cavity at high pressures and speeds, whereas low-pressure die-casting molds and gravity die-casting molds are filled at a much slower pace.

Low-pressure die casting is typically less expensive (requires less tooling) and results in lower levels of cast porosity. However, high-pressure die casting should be used for parts with thin walls (less than 3 mm thick) due to the ability of high pressure to force molten metal into the thin mold cavities. Once the molten metal is injected into the mold, it solidifies quickly, producing complex and detailed parts with high dimensional accuracy. 

What Are the Two Types of Die Casting?

Die casting can also be classified by the temperature of the mold or chamber. The two most common temperature-classified metal die casting methods are cold-chamber and hot-chamber die casting. 

Cold-Chamber Die Casting 

Cold-chamber die casting involves introducing molten metal at room temperature into a separate shot chamber using a ladle or pouring method. The shot chamber contains a ram that vertically forces the molten metal into a steel mold (die) with movable and fixed sections. The ram applies pressure ranging from 2,000 to 20,000 PSI to propel the molten metal into the die. The pressure is maintained until the metal cools and solidifies, after which the finished product is ejected from the die. This method is suitable for high-melting-temperature alloys like aluminum.

Hot-Chamber Die Casting

Hot-chamber die casting is a metal casting process specifically designed for low-melting-point alloys like zinc, tin, lead, and magnesium. This process is the most common and faster method than cold-chamber die casting. In this method, the metal is melted within the casting machine, in a furnace connected to the machine. A hydraulic system injects molten metal into the die under high pressure. This process is efficient for producing intricate shapes with high-quality materials that have lower melting points. Still, it is not suitable for alloys with higher melting points due to the risk of damaging the pump that injects the molten metal.

What Are the Steps Involved in Die Casting?

Die casting involves the following steps:

1. Preparing the Die: The first step is to create the die. Dies are typically made from steel and are designed to endure high temperatures and pressures. The mold design starts with a CAD (computer-aided design) drawing of the mold. This file is used to make the mold using CNC (computer numerical control) machining. After the die is made, it is prepared with a releasing agent or lubricant. This helps release the cast part. The die is then clamped and closed with high pressure. 
2. Metal Preparation: In the next step, the metal is prepared for the injection process. The metal, typically an aluminum, zinc, or magnesium alloy, is melted using a furnace and poured in a ladle. 
3. Metal Injection: The molten metal is poured into the shot chamber. This chamber is hot for hot-chamber die casting and cold for cold-chamber die casting. After that, the molten metal is injected into the die using high pressure. 
4. Cooling: The mold is allowed to cool and solidify into the shape of the mold. 
5. Ejection: After cooling, the part will be hard and completely solid and can be removed from the die. 
6. Trimming: The final step of die casting is the trimming step. This involves removing any excess metal found on the product. This is done by using a saw or trim die.  

What Are the Most Suitable Materials for Die Casting?

Many different metals (primarily nonferrous alloys) are compatible with die casting. The three most common materials are:

Aluminum Alloys

Aluminum alloys are widely employed in die casting due to their unique properties. Notable alloys such as 380, 360, 390, and 413 exhibit high operating temperatures, outstanding corrosion resistance, low density, excellent strength, and good thermal conductivity. Additionally, aluminum alloys offer good stiffness, a favorable strength-to-weight ratio, EMI and RFI shielding properties, and recyclability. They can also withstand high temperatures and retain dimensional stability with thin walls.

Zinc Alloys

Zinc alloys, including Zamak #2, #3, #5, #7, ZA8, and ZA27, offer a balance of strength, toughness, firmness, and cost-effectiveness. These alloys are known for their improved castability, shortened cycle time, and extended die life. The mechanical qualities of zinc alloys rival and exceed other common die-casting materials such as aluminum, magnesium, and bronze. Their exceptional casting fluidity contributes to thin-wall castability, resulting in smaller, lighter, cost-effective components.

Magnesium Alloys

Magnesium, particularly the AZ91D alloy, stands out for its toughness, durability, lightweight nature, and good castability. With a weight 75% lighter than steel and 33% lighter than aluminum without compromising strength, magnesium alloys are preferred for applications requiring complex casting with tight tolerances. The material’s excellent corrosion resistance further enhances its appeal. Magnesium alloys in die casting offer a valuable combination of strength and weight reduction, making them suitable for various industrial and automotive components.

Other Die Casting Alloys

Besides the primary materials, die casting can involve other alloys such as bronze, copper, brass, lead, and tin. Tin, for example, is known for its high fluidity and low melting point, leaving minimal wear on molds. On the other hand, bronze, specifically white bronze, finds application in the jewelry industry due to its low melting point, resembling white gold and stainless-steel alloys. 

Applications of Die Casting

Die casting has many applications in various industries. Some of the most common applications include:

1. Automotive: Many automotive parts, such as gears, pistons, and housings, are made using die-cast parts.
2. Aerospace: Die-cast aluminum is especially popular for aerospace components due to its lightweight.
3. Electronics: Electronic housings and connectors are commonly made from die-cast aluminum, zinc, or magnesium, providing good shielding from radio frequency interference (RFI) and electromagnetic interference (EMI).
4. Construction: Window frames, cladding, and other structural components are commonly made from die-cast metals, especially aluminum.

Advantages and Disadvantages of Die Casting

Die casting offers the following benefits and advantages:

1. Fast cycle times.
2. Is suitable for producing complex parts.
3. Produces parts with high dimensional accuracy.
4. Produces parts with a smooth surface finish, which lessens the need for post-processing.
5. Offers repeatable, accurate results with efficient production. This leads to cost-effectiveness for large production runs.

Die casting also has the following drawbacks and disadvantages:

1. The cost of equipment and dies can be very expensive.
2. Is typically unsuitable for ferrous metals or metals with a high melting point.
3. Designing and tooling new dies is a complex process that can take long before a production run starts.
4. Up-front costs and lead times may be prohibitively high with small production batches. More than small numbers of parts may be needed to recoup the large up-front investment.

Frequently Asked Questions 

Why Is It Called Die Casting?

Die casting is named for using dies – steel molds crafted primarily through CNC machining. These dies, consisting of a fixed, stationary half attached to the casting machine and a movable ejector half, serve as the molds into which liquid metal is injected.

What Is the Difference Between Mold and Die Casting?

Die casting and permanent-mold casting are two key methods in metal part production. Die casting injects molten metal into a steel mold under high pressure, ideal for small to medium-sized parts like those made of zinc, aluminum, and magnesium. It offers high precision, complex shapes, and efficient production rates. On the other hand, permanent mold casting pours molten metal into a reusable mold, typically made of steel or cast iron, suitable for larger parts composed of alloys like brass, bronze, and iron. Permanent mold casting is cost-effective, supports a variety of materials, and produces parts with high strength and good surface finish. The choice between the two depends on factors such as part size, complexity, and material properties.

Is Die Casting a Precision Casting Process?

Yes, die casting is generally considered to be precision casting. 

Is Post-Machining Always Required after Die Casting?

Aside from trimming or deburring operations, post-machining your parts is not necessarily required after die casting. Post-die-casting machining may be required for the final part if tight tolerances or specialized surface finishes are required, etc.

What Is the Difference Between Forging and Die Casting?

Casting involves heating metal in a furnace until it reaches a molten state. In this liquid form, the metal is poured into a die or mold to take on the desired component shape upon solidification. On the other hand, forging utilizes a combination of thermal and mechanical energy applied to ingots, causing the alloy to change shape while remaining in a malleable but solid state. Casting relies on transforming metal from liquid to solid within a mold. At the same time, forging achieves shape alteration by applying heat and force to a solid metal form.

Die Casting Services

Die casting is a popular metal fabrication process due to its accuracy, efficiency, and low cost. Although pretty straightforward, this process requires expert knowledge and experience, which makes outsourcing to the right manufacturing service provider essential. Fictiv consists of a team of knowledgeable and experienced engineers. We pride ourselves on delivering the best quality products according to our customers’ needs. Create a free account with Fictiv or upload your design for a free, instant quote.

Superhydrophobic coatings having a self-cleaning ability and anticorrosion performance are desired in many industrial contexts; however, high costs and complex fabrication methods usually limit their application.

In a new study, thin anticorrosive superhydrophobic coatings were prepared by a scalable, simple, and inexpensive spraying method to protect AA2024-T3 surfaces. The two-component coatings were designed using fluoropolyurethane and varying concentrations of surface modified silica nanoparticles.

Increased contact angles

Increased silica nanoparticle concentrations up to 10 wt% led to increased contact angles from 92° to 167°. The lowest contact angle hysteresis was obtained for the coating containing 4 wt% nanoparticles. FE-SEM images showed that high concentrations of nanoparticles (more than 4 wt%) led to cracks in the coating surface. The best performance of a coating was observed when the coating contained 4 wt% nanosilica particles, resulting in a 164° water contact angle, almost 60 days of surface protection, an impedance value of 2.2 × 10⁹ Ω·cm², 0.9% water uptake, and marked adhesion strength. The impedance value of the coating with 4 wt% nanosilica particles was about 25× that of the blank sample.

The study has been published in Progress in Organic Coatings, Volume 169, August 2022.

Ligue 1 side Lorient have reached an agreement with ESTAC Troyes for the transfer of young winger Jimmy Cabot worth €1.8m.

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The player is understood to have reached a 4.5 year contract agreement with Les Merlus, with just loose ends left to tie up in the coming hours.

It is unclear at the time of writing whether or not the player will be loaned back to ESTAC Troyes until the end of the season.

I know this is probably a controversial opinion, but I'm going to say it: Adele is the best. Her voice, her eyeliner, her hair. I mean, even when she had mic problems at the Grammys, her voice still sounded amazing and she handled the situation like a total pro. Her perfection streak just kept rolling at last night's Brit Awards. The 27-year-old singer picked up four awards and supported Kesha during her acceptance speech. Oh, and she did all of that while wearing an inexpensive drugstore product on her lips.

Makeup artist Michael Ashton used a combination of lip liner and Lucas' Papaw Ointment to create Adele's stunning bold red lip. Sadly, Ashton couldn't reveal the exact lip liner shade he used, but we love how accessible his method of dabbing a bit of the $9 ointment over it is.

For the rest of the look, Ashton relied on the British company Ex1 Cosmetics. He used the Ex1 Invisiwear Foundation and the Ex1 Delete Concealer to smooth out her complexion. Ashton also added a bit of the Ex1 Blusher in Pretty in Peach to give her cheeks some color. And for that smoky eye? Ashton relied on the Tom Ford Eyeshadow Palette in Nude Dip. Glad to know we have one thing in common with Adele, even if it's just loving the same lip ointment. Baby steps, people.

Adele reveals her favorite body part:

Premier League side Aston Villa’s manager Remi Garde has spoken to French radio station RMC about his current situation, amid speculation suggesting that the former Lyon manager would be about walk out.

“Of course, I would have liked to have had players [in the transfer window]. I had pinpointed certain elements, but it did not happen for several reasons. Already our football situation is not particularly motivating. There is the possibility that we will be in the Championship next year. The American owner has also lost £300m. Instead, he might want to do something else. As long as it is mathematically possible, I believe. Aside from that, it is not a mystery, the club has been fighting for four years not to go down…”

“The squad and the players have potential, but it remains a reduced group. They have broad enough shoulders to play in the Premier League. They have shown that since I arrived. That is to their credit. Now I think that there was a bit of confusion with the former manager.”

“With Tim Sherwood, things simply didn’t stick. They lost seven of their first ten matches. When you arrive in England, all individuals coming from the continent have difficulties in terms of adapting. There are specifics that are sometimes surprising. The French manager that I am has given them second wind.”

“[Objectives and whether or not he stays should they be relegated] will be rediscussed once the next season begins its preparation. That means at the end of the campaign. I am ready to stay at this club if I am given the means required for promotion. Aston Villa is a prestigious club in England on the exterior. But inside, there are lots of things that need to be done…”

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“My aim in the short term is not to return to France. I have nothing against France, but I like a lot what happens here. We will see about a return much later.”

Zlatan Ibrahimovic has given a pre-match press conference ahead of PSG’s 2nd leg Champions’s League encounter with Chelsea at Stamford Bridge tomorrow evening.

On whether this match is about revenge for Ibrahimovic:

I have never thought about revenge, or those type of things. The past, is the past, I am thinking about the present. I just want to remain on the pitch for as long as possible, to do what I know how to do, to play football. The Chelsea players who behaved liked babies? Tomorrow is another match. The last time, it was like nothing I have seen. I did not expect that sort of behaviour from those sort of players.

Can I finally win the Champions’s League? Age is a feeling. I do not feel old. With maturity, I have told myself that this would not change the player that I am if I do not win it. But, I would be very happy to win it. I have won a lot of trophies with a lot of clubs. This year, I have the chance to win it. I am going to try.

On coming to the Premier League: 

These months with PSG and the Euros, that is what I am thinking about. I am not going to decide today. I am not currently discussing anything. I am not worried. There will be offered. The future looks good for me.

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On the difference between Chelsea and PSG:

This project started 3.5 years ago. Chelsea’s one started over 10 years ago. With time things come. Believe me, the Qataris will chase after the Champions League until they have it. With or without me. This is a new project. I am part of it. Give us some time and you will see. They have moulded a very good team. We have not yet gone further because we were lacking a little in experience.

On John Terry’s injury:

I would like him to play. I missed him. With him, it is Chelsea’s best team. I prefer to play with the best. But, in the previous game, without him, it was difficult. This is a challenge for us.

On the match:

We are ready, we have prepared ourselves well in recent weeks. Tomorrow is the match. The entire team has come to London. We are ready, play. The key to victory? There is maybe a secret, but I will keep it to myself. This match will be different, we will follow the instructions of the coach. We have not yet spoken about tactics or strategy. With the 2-1, the situation is different.

Italian football reporter Gianluca di Marzio claims that the possible contract extension of Zlatan Ibrahimovic at PSG is “very complicated”.

His report claims that MLS, China, Chelse and Manchester United are set to court the Swede.

As for a possible move to Italy, it would be extremely difficult, but Ibrahimovic does not discount it, so AC Milan have a very outside chance.

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Time to read: 5 min

The world of CNC machining services can be overwhelming — I’ve personally gotten turned around by all the CNC machining jargon before. There’s a whole dictionary of commonly used acronyms and when you head to research what they mean, there isn’t a lot of data available. 

Within the CNC milling machine classification, there are many types you can utilize, but in general, a CNC mill will either be horizontal or vertical. A CNC vertical mill machine has a spindle (cutting tool) fixed in its vertical orientation, perpendicular to the horizontal bed. They use cylindrical cutters oriented vertically on the spindle axis and come down on the workpiece.

CNC milling provides a variety of cuts and can be performed on a variety of metals and non-metals, such as ABS, aluminum, brass, bronze, copper, Delrin, Kovar, magnesium, PVC, PTFE, stainless steel, Teflon, zinc, and more. Read on to learn more about the benefits of CNC milling, a comparison of types of CNC mills, and the best type of vertical CNC milling machine.   

Applications and Advantages of Vertical CNC Milling Machines

CNC vertical milling machines are advantageous because they can provide quick processing times along with the precision and accuracy you need for even the most complex machining jobs.

Some common applications include:

• Large part machining
• Slots
• Helical grooves
• Reamer
• Bevel gears
• Toolroom work
• Mold manufacturing
• Complex geometry machining

CNC Vertical Mold/Die Mill

A CNC vertical mold/die milling machine is utilized for high-precision, high-accuracy machining. A mold machine is primarily utilized to manufacture, you guessed it, molds! They are also utilized for tool & die machining as well as other high-performance machining work. 

In general, CNC vertical mold/die mills have the following characteristics:

• High spindle speed (5k – 30k RPM)
• Feed rates as high as 600 inches/minute
• Excellent surface polish results, as low as a fraction of a micrometer Ra
• Excellent, smooth fitting clearance for fitting molds
• High pitch accuracy
• Great and constant Z-axis control
• High torque spindle motor (i.e. 90 ft-lb @ 2k RPM)
• Typically consist of 3-5 axes
• Thermally stable platform

CNC vertical mold/die mills also offer the following benefits:

• High accuracy and precision to reduce lead time and cost
• Excellent surface finish reduces post-processing finishing operations
• Dynamic accuracy due to machine rigidity
• Hard milling enables mold components to be machined as-hardened, allowing for a reduction in machining complexity and post-processing hardening

CNC Vertical Toolroom Mill

A toolroom mill is classified as such because they are typically found in – and you’re not gonna believe this – toolrooms. A toolroom is typically a place where machinists make tooling for other CNC machines, including production CNC machinery. Of course, such mills can also be found in labs, teaching environments, and schools. 

As precision, tight tolerances, and accuracy are critical for production tooling, a CNC vertical toolroom mill tends to be more precise. This type of CNC mill is typically smaller and requires more (or all) manual operator control and manual tool changes as well. Vertical toolroom mills also typically have a reduced number (2 or 3) of operational axes. Some CNC vertical toolroom mills have the option to be run completely manually or with CNC controls.

 CNC vertical toolroom mills have the following characteristics:

• Relatively simple to use, even if you don’t understand coding or CNC programming
• Spindle speed in the range of 4k to 6k RPM
• Impressive torque at an affordable price (i.e. 33.0 ft-lb @ 1200 RPM)
• Cutting speeds that rival larger CNC mills (around 400 inches/minute)
• A majority have manual controls as well as CNC controls

CNC vertical toolroom mills offer the following benefits:

• Precision performance at an affordable price
• Versatile — can perform a wide array of machining tasks
•  High reliability
•  Some can operate on a standard power supply (220 VAC)
• Superior accuracy and precision
• Can be utilized as a teaching machine
• Excellent spindle nose to tabletop ratio (better than standard vertical CNC mills)
• Higher rigidity than standard vertical CNC mills

CNC Vertical Drill/Tap Mill

A CNC vertical drill and tap mill offers the ability to perform precision drilling and tapping, along with full milling capabilities. These mills perform high-speed tapping while maintaining rigidity to get the accuracy required. Non-cutting time is typically reduced with these machines due to the rapid feed rate and higher than standard acceleration rates. These are ultra-productive machines with compact footprints. 

CNC vertical drill/tap mills have the following characteristics:

• Fast spindle speed in the range of 10k-20K RPM
• Impressive torque at an affordable price (i.e. 33.0 ft-lb @ 1200 RPM)
• Superior cutting speeds (around 2k inches/minute) 

CNC vertical drill/tap mills offer the following benefits:

• High productivity with a small footprint
• Full milling capabilities coupled with precise and accurate drill and tap machining
• High-speed rigid tapping
• Reduced cycle-times
• Specially optimized for machining die-cast parts
• High-pressure coolant capability 

CNC Vertical Gantry Mill

CNC vertical gantry-style mills exist primarily to meet the need for machining both large workpieces and even the smallest parts at quantities of a few thousand a time. A gantry-type mill has a gantry frame, along with a large horizontal bed. The gantry mill can cut metals and plastics alike and can cut parts from sheet metal. 

CNC vertical gantry mills have wide tables and can handle parts up to several inches or even a foot thick — so they can handle a lot of weight and have several feet of travel. They are capable of machining even the largest and toughest to handle parts, including 5-axis, complex machining jobs.

CNC vertical gantry mills have the following characteristics:

• Fast spindle speed in the range of 10k-20K RPM
• Good torque (i.e. 11.3 ft-lb @ 7500 RPM)
• Good cutting speeds (around 800 inches/minute) 

CNC vertical gantry mills offer the following benefits:

• Dual-axis spindle head
• Excellent for machining larger components, such as those found in the aerospace or composite structure industries, and layup molds
• Excellent cutting platform stability
• Versatile enough to perform traditional complex machining as well as cutting large parts and sheet metal 
• Reduced process times for loading and unloading the CNC mill because of the bridge found on most gantry mills
• Efficient, productive, accurate machining

CNC Vertical Column Mill

A CNC vertical column mill offers ultra-high efficiency. A vertical column mill style machining center has a fixed table and a vertical column where all the X, Y, and Z axis movement occurs. As the name implies, a vertical column mill consists of a vertical column with the spindle attached. The column also houses the mechanism which provides the drive functionality to the spindle. 

There are also double column mills that provide extra stability, precision, and accuracy. The large table, which moves longitudinally, allows for manufacturing productivity gains because you can load a multitude of parts on a table at one time — reducing the need for single part loading and unloading. The large table also allows for the machining of otherwise difficult-to-machine large or heavy pieces (similar to gantry-style mills).

CNC Vertical Drill/Tap Mills have the following characteristics:

• Fast spindle speeds in the range of 4K-8K RPM
• Great torque (i.e. 110 ft-lb @ 300 RPM) 

CNC Vertical Drill/Tap Mills offer the following benefits:

• Versatile, customizable, and adaptable
• Increased precision
• Easy to maintain due to simple construction
• Great at machining undercuts, heavy cuts, multi-sided components, and complex surface contours
• Can handle heavy parts — up to10000 lbs!
• Superb at machining for industries like aerospace, alternative energy, and oil/gas

Sourcing Simplified

Many metal and plastic parts can be cut utilizing the vertical CNC machining technologies discussed in this article. But you don’t have to figure out the best manufacturing process for your parts alone. If you’re tasked with sourcing and supplying mechanical parts, Fictiv is your operating system for custom manufacturing that makes it faster, easier, and more efficient. 

In other words, Fictiv lets engineers, like you, engineer. We offer a range of manufacturing capabilities to produce both simple and incredibly complex geometries — create a free account and upload your designs today!

Speaking in an interview with Téléfoot, France boss Didier Deschamps gave his clearest indication yet that Dimitri Payet will be selected in Les Bleus’s squad for the upcoming EURO 2016 championships.

“If I take him, it is because I am convince that he can bring us something. He has a particular set of skills and knows how to play others into the game. I think that the question no longer asks itself…”

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Speaking following Manchester City’s qualification for the semi-finals of the Champions League, French central defender Eliaquim Mangala reacted with joy.

“This is an important moment for us, an important moment in our careers. We said that we wanted to make our mark on the history of the club, for the moment we are on the right route and we need to continue in this way. To play matches like this, in the quarter final, against PSG, of course it makes you happy. I enjoyed myself and that is important. We knew that this would be a difficult match. I tried to give my best and that allowed me to succeed.”

“The most important thing was to qualify even if France is sad it can at least say that French players will be playing in the semi-finals. I am concentrated on my club… At PSG, they have a very good team, very good players, but the fact that they became champions quite early might have caused them to let go a little. What is certain, is that in the quarter finals there is no such thing as a good or bad draw. We can say that one club or another are favourites, but only the pitch tells you the truth and that is what we showed over the course of these two matches.”

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