Die casting is a process of casting Aluminium, Zinc and Copper alloy under pressure, which produces precision parts in high volume with low cost. There are two processes of die casting: hot chamber die casting and cold chamber die casting. Die casting machines are typically rated in the amount of pressure they exert on the die. Regardless of their size, the only fundamental difference in die casting machines is the method used to inject molten material into a die. A complete die casting cycle can vary from one second for small components to minutes for casting a large part, making die casting the fastest technique available for producing precise metal parts. Supply Concepts utilizes the fastest methods of production in Asia to produce quality products at significantly lower cost than in other regions.
- Die casting is an economical process providing a wider range and shapes of components than any other manufacturing technique.
- Die cast parts have a long service life and can be manufactured to complement or enhance the visual appeal of the final product they are used in. Many product designs can be improved or benefit by utilizing die cast parts.
- Die casting provides for complex shapes and higher dimensional accuracy/stability than many other mass production processes. Some further machining may be required, depending on the design or application
- Die cast parts are stronger than plastic injection moulded products having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods.
- Die cast parts can be produced with smooth or textured surfaces and they can be easily finished with a minimum of surface preparation.
- Die castings can provide integral fastening elements as part of the design. For many parts, post-machining can be totally eliminated, or, done minimally to bring dimensions to sizes required.
Extrusion is the process by which long, straight metal parts can be produced. The cross-sections that can be produced vary from solid round, rectangular, L shapes, T shapes, Tubes and, many other different types. Extrusion is done by squeezing metal into a closed cavity through a tool, known as a die, using either a mechanical or hydraulic press.
Extrusion produces compressive and shear forces in the stock. No tensile is produced, which makes high deformation possible, without tearing the metal. The cavity in which the raw material is contained is lined with a wear resistant material. This can withstand the high radial loads that are created when the material is pushed by the die. Extrusions often minimize the need for secondary machining, but, are not of the same dimensional accuracy or surface finish as machined parts.
Typical parts produced by the hot extrusion process are trim parts used in automotive and construction applications, window frame members, railings and aircraft structural parts.
Die casting is one of the fastest and most cost-effective methods for producing a wide range of components. However, to achieve maximum benefits from this process, it is critical that designers collaborate with the die caster at an early stage of product design and development. Consulting with the die caster during the design phase will help resolve issues affecting tooling and production, while identifying the various trade-offs that could affect overall costs. For example, parts having external undercuts or projections on sidewalls often require dies with slides. Slides increase the cost of the tooling, but may result in reduced metal use, uniform casting wall thickness or, other advantages. These savings may offset the cost of tooling, depending upon the production quantities, providing overall economies realized over the life of the project.