Die casting is an extremely popular manufacturing process for creating metals products. Die cast parts produce high quality, uniform pieces that can be created in just about any size, part geometry, surface texture, or finish. They can require minimal secondary processes since many features can be integrated into the design such as studs, hinges, drill holes, and bosses, to name a few.
Die Casting Types Available from Papler
Papler partners with die casters that utilize the latest die casting technology to deliver high-quality, on demand parts. Our offering focuses on the two leading types of die casting: hot chamber casting and cold chamber casting. Both types can produce parts with complex geometry, close tolerances, and robust mechanical properties.
Hot Chamber Die Casting
Also known as gooseneck casting, the hot chamber die casting process is the most popular die casting process. It is optimal for working with lower melting point alloys such as zinc, magnesium, and lead. A holding pot is filled with metal and heated with hot chamber die casting until molten by an attached or built-in furnace. A feature of the hot chamber system referred to as the gooseneck forms a holding chamber within the pot and a nozzle-like pathway that connects to the injection cavity of the fixed half of the die. A plunger that sits above the chamber allows it to fill with molten metal from the holding pot. When the chamber is loaded, the plunger lowers and forces molten material up the gooseneck into the die cavity. The mold is held together under pressure while the metal cools and solidifies in the mold. Once the metal is cool enough, the dies open, and the casted piece ejects via ejector pins.
Cold Chamber Die Casting
With the cold chamber die casting process, the chamber remains at room temperature and does not have a holding pot of molten metal. Metal is melted in a separate furnace and deposited into the shot chamber through a pouring hole by hand with a ladle. In cold chamber die casting, the mold is connected directly to the shot chamber and does not utilize a plunger system. Instead, a ram forces molten metal into the mold and held under high pressure while the metal solidifies. This type of die casting is suitable for comparatively higher melting temperature materials such as aluminum.
Die Cast Metal Materials
Several different metal materials are available to choose from when manufacturing using die casting. The material you choose will depend on your intended use for the product. For instance, cast aluminum parts are common in aerospace or automotive applications where corrosion resistance and weight reduction are essential factors. You can learn more about the main types of die casting materials we offer in the sections below. If you have a specific material request, just let us know!
Aluminum Die Casting
Aluminum alloys are the most widely used for die cast parts. Aluminum die casting suppliers benefit from the total recyclability of the material and its ease of use. Due to the comparatively higher melting point, aluminum die casting may require a cold chamber casting process. Engineers use cast aluminum part primarily for their great strength to weight ratios, dimensional stability, and diverse finishing options. Some of the other common characteristics of aluminum alloy casting are:
Engineers and designers can choose from a wide range of alloys for their aluminum casting parts. Papler offers the most popular aluminum die casting alloys, including:
Zinc Die Casting
Zinc is the easiest to cast material among the die casting metals and is typically used in hot chamber processes. Molten zinc has exceptional casting fluidity and a lower melting point. Its strength and stiffness allow it to produce parts with thinner walls and highly detailed features and maintain tight tolerances. The low melting point of zinc alloy die casting means the casted parts cool off and solidify more quickly, which results in the fastest production rates of the die casting materials. Zinc is an all-around well-performing material due to its balance of mechanical and physical characteristics, which include:
Papler offers the most popular types of Zamak and ZA die casting zinc alloys. More specifically, those alloys include: