Die casting, as a production process, is popular for its ability to fabricate parts that are uniform, with superior quality surface finishes, and with high design accuracy.
In most cases, die casting here in the UK eliminates or reduces post-production machining requirements, shortens fabrication time, and raises the process cost-efficiency.
Sturdy metals are not easy to die cast, including steel of specific grades. However, there are various kinds of alloys that are ideal for die casting.
Comparatively easy to die cast, zinc-based materials respond well to the process of die moulding. The alloy is comprised of several metals at specific ratios. Typically, a work piece used for zinc-based die casting has a typical composition of 86% zinc, 7% to 10% tin, and 4% to 7% copper.
More tin means a more flexible work piece, while higher levels of copper provide more rigidity. Fabricators use zinc alloys instead of brass or cast iron, but with less tensile strength.
Tin-based alloys find frequent use in applications that require high resistance to corrosion like external and internal bearings, as well as products for the food industry.
The metal proportion for tin-based allows vary widely, but in most cases, 90% tin, 6% antimony, and you use 4% copper to ensure the material’s durability.
Bronze and Brass Alloys
Most materials based on bronze and brass are as effective for die casting as zinc-based materials, but drilling small holes on the work piece is possible after the casting process, and not during.
You typically use bronze and brass to fabricate camshaft components, washers, and decorative items (because of the good potential for surface finishes and distinct colour.) Bronze and Brass Alloys typically have a 60% copper, 40% zinc ratio, although there are many other variations used.
There are many other common types of alloys used such as aluminium alloys, and lead alloys. The kind of alloy used for a die casting job depends on the material properties and composition.