Die Casting

ForceBeyond provides superior quality custom die casting parts and components for a wide range of industries including automotive, food dairy, machinery, medical, plumbing, watering, mining, petrochemical, electrical, energy, aerospace, submarine and others.

Our die casting machines range from 180 up to 2,000 metric tons, we can produce die casting parts from a few grams to more than 100 pounds with superior quality ready for assembly. For die casting parts with requirements of esthetical, functional, or protective coatings, we also offer a broad range of surface finishing including powder coating, e-coating, shot blasting, chrome plating, and bright finish.

What Is Die Casting?

Die casting is a metal casting process characterized by pressuring molten metal into the mold cavity. The mold cavity is created using two hardened tool steel molds that are machined during processing and work similarly to injection molds. Most die-castings are made from non-ferrous metals, especially zinc, copper, aluminum, magnesium, lead, tin and tin-based alloys. Depending on the type of metal being cast, thermal or cold machines are used.

How are Die Castings Made?

Steel dies capable of producing tens of thousands of castings in quick succession must be made in at least two sections to allow the castings to be removed. These parts are firmly mounted in the machine and are arranged so that one is stationary (fixed die half) and the other one is movable (syringe half-mold). To begin the casting cycle, the two mold halves are clamped together by a die-casting machine. Molten metal is injected into the mold cavity and rapidly solidified. The mold half is opened and the casting is ejected. Die-casting molds can be simple or complicated, with moveable slides, cores or other parts, depending on the complexity of the casting.

To date, the complete cycle of die casting has been the fastest cycle to produce precision nonferrous metal parts. This is in stark contrast to sand casting, which requires new sand molds for each casting. Although the permanent mold process uses iron or steel molds instead of sand, it is much slower and less precise than die castings.

Watch the video of our die casting facility to learn how die castings such as aluminum die castings, zinc die castings are made. Video also available on youtube.com.

aluminum die casting zinc die casting parts

Advantages of Die Casting

  • Simple or complex shapes
  • Thin wall thickness
  • Light weight
  • High rates of production
  • Corrosion resistance
  • Monolithic – combine multiple functions in one
  • Efficient and economical alternative to other processes
  • Thin wall thickness – up to 0.040 inch for small castings
  • Light weight – light alloys are used
  • Corrosion resistance – surfaces are smoother than other casting types
aluminum die casting parts sku 1

Die Casting Material Information

 

Material Tensile Strength (Mpa) Thermal Conductivity (W/mK) Features
Aluminum A380 325 96
  • Best combination of mechanical, casting, and the thermal properties.
  • Excellent fluidity, pressure tightness, and resistance to hot cracking.
  • Widely used for engine brackets, hand tools, electronic equipment chassis, gearbox cases, and household furniture.
Aluminum A360 317 113
  • Excellent pressure tightness and fluidity.
  • High corrosion resistance.
  • High strength in elevated temperatures.
Aluminum 413 295 121
  • Good combination of casting, mechanical, and thermal properties.
  • Excellent fluidity, pressure tightness, and resistance to hot cracking.
Aluminum 383 310 96
  • Often used for highly intricate components.
  • Good corrosion resistance, lightweight. 
  • Good combination of casting, mechanical, and dimension stability. 
Aluminum B390 317 134
  • High hardness and good wear resistance.
  • Suitable for internal combustion engine pistons, cylinder bodies for compressors, and brakes.
Aluminum A413 290 121
  • Excellent pressure tightness.
  • Good choice for hydraulic cylinders. 
  • Suitable for die casting intricate components.
ZAMAK 2 359 105
  • Excellent damping capacity and vibration attenuation.
  • Superior to other Zamak alloys with creep performance.
  • High strength and hardness levels after long-term aging
ZAMAK 3 283 113
  • Great balance of physical and mechanical properties.
  • Excellent finishing characteristics for plating, painting, and chromate treatments.
  • Good castability and long-term dimensional stability.
  • Good damping capacity and vibration attenuation.
ZAMAK 5 328 109
  • Has a higher copper content than Zamak 3, which results in higher strength.
  • Has less ductility than Zamak 3.
  • More readily plated, finished, and machined than Zamak 3.
ZA 8 374 115
  • Ideal for decorative application.
  • Excellent finishing and plating characteristics.
  • Good performance of strength, hardness, and creep properties.

Secondary Operations of Die Casting We Offer

  • High precision CNC machining, milling, drilling, tapping, e-coating, anodizing
  • Painting, sanding, shot blasting, powder coating, chrome plating

Aluminum Die Casting Parts and Zinc Die Casting Parts

 

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Sources

Our Internal Resources for Die Casting, Investment casting, Forging and Sand Casting