Die Casting

Die Casting: The way to go for rapid production

of aluminium and zinc alloy parts

As a Die Casting specialist, Omnidex offers a lot more than what a typical factory can do for you. From die making to production engineering and QC, we can set everything up for you. There are a lot of things to consider in a Die Casting project, and here are what we think really matter to you.

We have been working with some of the best Die Casting factories in our region for many years. These factories can produce top quality products with highly accurate dimensions and tolerances. Also, you are not limited to the capacity of just one manufacturer, giving you more choice on materials and casting methods.

Your project is backed by our team of experienced in-house engineers. We use the very latest software to simulate molten metal flow during the Die Casting process so that we can highlight feed points and identify areas where improvements can be made. We are always ready to answer your questions concerning Die Casting and other manufacturing processes.

The die is the most important component in the process. Any problem in the die design may lead to inaccuracy or quality issues in the products. As an expert in Die Casting, we will provide you with the best die designs possible to ensure the success of your project.

Our production offers impeccable surface finishes through detailed final cleaning and specialized painting. We also guarantee clean sprue removal and keep waste to a minimum.

Issues such as flash, unfilled sections and hot tearing may occur in Precision Die Casting. Our QC specialists will make sure the product is free of these problems, and the dimensions and properties are up to the agreed specification throughout the entire production run. Learn more about our QC process here.

Learn more about Die Casting

The Die Casting process dates back to the early 19th century when tin and lead were poured into steel molds to produce type for printing. This process is characterized by forcing molten metal under high pressure into a mold cavity. Its potential was soon exploited and today it is used in virtually every industry.

Check out our video to learn about the steps in the Die Casting process:

There are 3 types of Die Casting methods:

This process involves heating metal in a separate furnace, then transferring the molten metal into the casting machine. It is used for metals with a higher melting point, such as aluminum, magnesium and copper.

Instead of using a separate furnace, metal is heated inside the casting machine. The injection mechanism involves a goose-neck machine placed inside a crucible, which can heat the metal to melting point and inject it into the die. It is typically used for metals with lower melting points such as zinc alloys. (Thanks to technology advancement, magnesium alloys can also be used.)

Multi-slide die casing uses tools with 4 perpendicular slides (in some cases up to 6 slides at angles other than 90°) to produce more complex and accurate castings. This process is used to produce small zinc alloy components at a rapid production rate (up to 4500 cycles per hour).

Die Casting Animation China

Pros and cons of Die Casting:

Pros

Cons

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Die Casting China

Materials

It is best to use non-ferrous alloys such as aluminium, magnesium, zinc, brass and copper alloys for Die Cast Metal.

Aluminum Alloys

Commonly used in handheld devices, electronic and telecommunication components and computer parts, aluminium die castings are not only lightweight, but also able to withstand the highest operating temperatures when compared to the other alloys.

Characteristics of aluminium alloys in Die Casting:

Lightweight
Able to withstand the highest operating temperatures when compared to the other alloys
Good resistance to corrosion
Higher electrical and thermal conductivity
Low density and high dimensional stability
Good strength and stiffness to weight ratio
Fully recyclable
Excellent EMI shielding properties
Good finishing characteristics
Only suitable for cold chamber machines

Aluminium alloy composition:


Percentage of alloying material	A380	A383	A413
Copper	3.0 – 4.0	2.0 – 3.0	1.0 (maximum)
Iron	1.3 (maximum)	1.3 (maximum)	2.0 (maximum)
Magnesium	0.1 (maximum)	0.1 (maximum)	0.1
Manganese	0.5 (maximum)	0.5 (maximum)	0.35
Silicon	7.5 – 9.5	9.5 – 11.5	11.0 – 13.0
Zinc	3.0 (maximum)	3.0 (maximum)	5.0
Nickel	0.5 (maximum)	0.3 (maximum)	0.5 (maximum)
Tin	0.35 (maximum)	0.15 (maximum)	0.15
Other (in total)	0.5	0.5	0.25
Aluminum	Remainder	Remainder	Remainder

Magnesium alloys

Magnesium alloys are extremely light and durable but difficult to machine. It is used to make products where lightweight and durability is necessary, such as high-end electronics and camera components. Out of all the alloys used in die casting, it is the lightest and easiest to machine.

Characteristics of magnesium alloys in Die Casting:

High strength to weight ratio
Very low density
Excellent EMI and RFI properties
High electrical and thermal conductivity
Good resistance to corrosion
Can withstand high operating temperatures
Can be made exceptionally thin with high dimensional accuracy and stability
Good finishing characteristics
Suitable for both hot and cold chamber machines

Alloy AZ91D is a high-purity magnesium alloy widely used in die casting alloy. It offers an excellent combination of corrosion resistance, castability and mechanical properties. It has the following properties:


Mechanical Property	Magnesium Az91D
Hardness	63 Brinell
Elongation	3% in 50mm
Tensile Strength	230 MPa / 34psi
Yield Strength (0.2% offset)	160 MPa / 23 psi
Shear Strength	140 MPa / 20 psi
Impact Strength	2 ft. Ib.

The physical properties of Magnesium AZ91D are as follows:


Physical Property	Magnesium AZ91D
Density	1.81 g/cm²/ 0.66Ib/in²
Electrical Conductivity	12.2% IACS
Thermal Conductivity	72.3 W/m – K / 41.8 Btu-ft/h-ft °F
Coefficient of thermal expansion	25.5 µm/m°K / 14 µin / in °F x 10^-6
Melting Range	470 °C – 595 °C (875 – 1105 °F)

Zinc alloys

Zinc alloys are easiest to die cast and is a good low-cost alternative to fabricating or machining parts. It is commonly used in consumer electronics, computers, telecommunications and the automotive industry. Used in hot chamber machines, zinc alloy die castings have a smooth surface finish, allowing for plating and painting.

Characteristics of zinc alloys in Die Casting:

A low-cost material
Able to form very thin walls
Easy to cast
Offers good impact strength
Fully recyclable
Lower melting point (longer die life)
High dimensional stability and accuracy
Outstanding resistance to corrosion
High thermal conductivity
High hardness and strength
Can be cold formed (easy for fastening and joining parts)

Zinc alloy compositions:


Percentage of alloying material	Zamak 2	Zamak 3	Zamak 5	Zamak 7	ZA8	ZA27
Aluminum	3.5 – 4.3	3.5 – 4.3	3.5 – 4.3	3.5 – 4.3	8.0 – 8.8	25.0 -28.0
Copper	2.5 – 3.0	2.5 maximum	0.75 – 1.25	0.25 maximum	0.8 – 1.3	2.0 – 2.5
Magnesium	0.02 – 0.05	0.02 – 0.05	0.03 – 0.08	0.005 – 0.02	0.015 – 0.03	0.01 – 0.02
Iron	0.1 maximum	0.1 maximum	0.1 maximum	0.075 maximum	0.075 maximum	0.075 maximum
Lead	0.005 maximum	0.005 maximum	0.005 maximum	0.003 maximum	0.006 maximum	0.006 maximum
Cadmium	0.004 maximum	0.004 maximum	0.004 maximum	0.002 maximum	0.006 maximum	0.006 maximum
Tin	0.003 maximum	0.003 maximum	0.003 maximum	0.001 maximum	0.003 maximum	0.003 maximum
Zinc	Remainder	Remainder	Remainder	Remainder	Remainder	Remainder

Brass alloys

Brass is an alloy containing zinc and copper. It offers a variety of aesthetically pleasing finishes, both as cast and polished.

Characteristics of brass alloys in Die Casting:

Properties of brass:


Property	Brass
Tensile Strength	55 ( psi x 1000)
Yield Strength	30 (psi x 1000 with 0.25 offset)
Shear Strength	37 ( psi x 1000)
Fatigue Strength	25 (psi x 1000)
Hardness	91 Brinell
Impact Strength	40 ft/lb

Copper alloys

Characteristics of copper alloys in Die Casting:

Cost the most to die cast out of all alloys
Offers high dimensional stability
High melting point (shorter die life)
High strength.
High resistance to corrosion and wear
Offer the highest mechanical properties compared to the other die casting alloys
Require the use of a cold chamber machine

Other alloys

(please consult our sales department for more information)

Die Casting Parts Tolerances

Die Casting tolerances are based not only on the alloys used, but also the length, shape and location of each feature. There are several considerations when it comes to setting tolerances for Die Casting parts:

Tolerances looser than required will result in poor product quality and lifespan, whereas tolerances higher than required will result in higher scrap rate and product cost, so it is important to strike a balance between different factors and achieve tolerances that are as tight as necessary.

Therefore, it is important to highlight the functional requirements, as well as the critical dimensions and features on the part that are critical. From here we may choose the appropriate process and material to meet all these specifications and requirements.

Here are the Die Casting tolerance standards for your reference:


Nominal dimension (mm)		Linear dimension Tolerances (mm)（ISO8062）
>	≤	CT4
—	10	0.26	±0.13
10	16	0.28	±0.14
16	25	0.3	±0.15
25	40	0.32	±0.16
40	63	0.36	±0.18
63	100	0.4	±0.20
100	160	0.44	±0.22
160	250	0.5	±0.25
250	400	0.56	±0.28
400	630	0.64	±0.32

Choose the right material for your Die Casting project

There are many factors to consider when choosing the material for your project. Each alloy has different properties that may or may not be suitable for certain usage. Depending on your requirements, there may be several materials suitable for your project, or you may be able to get better results with another casting process. We highly recommend exploring all the options with us before making your decision.

Want to learn more about other casting processes? Check out other processes on our website.

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