Withstanding Tolerances

Die casting, more than any other casting process, is capable of producing the tightest tolerances. Precision machined and polished to the micron level, die cast dies are made of H13 tool steel and can be used in a variety of applications. Because of the durability of the steel and the rapid solidification time of the process, tight tolerances can be produced consistently throughout the life of the die.

Weight to Strength Ratio

When you combine thin walls with a fine microstructure, the result is a casting that is both strong and lightweight, and it is difficult to match.

Microstructure is the way things are put together.

• The grain structure of a casting determines the properties of the casting, and this structure is formed as the casting solidifies

• A tight matrix of small grains is formed as a result of faster solidification

• Smaller grains have better physical properties because it is the grain boundaries, rather than the grains themselves, that are more likely to fail when under pressure

• Because of its superior solidification rate, HPDC produces the best overall properties

   

Tooling Expenses

When compared to other die casting processes, high pressure die die casting mould has a relatively high tooling cost. In die casting, dies are precision-engineered, heavy-duty steel molds that are capable of withstanding the injection and locking forces generated by the machine.

Because of the long tool life and the ability to design dies that can produce multiple parts at the same time, the higher tooling cost is offset by the lower part price for the part. The die cavities (the portion of the die that actually does the work) can typically withstand at least 100,000 cycles before they need to be replaced. Given that the holder block can frequently be refurbished and reused for several hundred thousand shots, the cost of refurbishing the die and adding new cavities will be approximately half of the initial investment.

Finishing the Surface

It is common for high-pressure die custom die casting to be used as a cosmetic focal point of a product because of the smooth surface finish that can be achieved through the process of finishing. This surface finish is achieved through the use of rapid fill times and smooth walls in the dies used in the casting process. Extremely high-pressure die castings can be blasted, painted or anodized and even polished to a mirror finish, depending on the application.

Cost of Casting

Because of the high production rate, the cost of high pressure die casting is typically less than that of other processes. High-pressure die casting machines can produce parts at speeds ranging from 60 to 120 cycles per hour, depending on the size of the component. It is possible to produce thousands of parts in a single shift when this is combined with the ability to use dies that have multiple cavities at the same time. As a result, the piece price is extremely competitive. Additionally, because die aluminum alloy die casting can have much thinner walls than other processes, the weight of the casting can be significantly less than other processes, resulting in a lower piece price due to the use of less metal.

Casting Dimensions

Die cast technology and machine size are constantly evolving, with larger and better machines becoming available. Casting size may have been a constraint in the past for high-pressure die casting, but that is changing rapidly. Many automotive and marine engine blocks are now produced using High-Pressure Die Casting on machines capable of handling 4500 tons. Currently, Tesla is in the process of installing a 6500-ton machine that will be used to cast a large portion of the Model Y's undercarriage.

It is heat treatable.

Heat treating isn't just for sand castings anymore; it's also for metal parts. Heated high-pressure die cast aluminum parts for structural applications in the automotive industry are now being used as a result of advances in technology. This is accomplished through the use of special alloys that minimize impurities such as iron, as well as the use of vacuum assist to create a casting with minimal porosity, which allows the aluminum casting to bubble during the heat treatment process.