Understanding Magnesium Die Castings And Processes

Die casting is used to refer to a casting process, which is done by forcing different kinds of highly pressurized molten metal into a mould cavity. This mould cavity is actually created by the use of steel dies, which are hardened and shaped by the use of a machine and are quite similar to injection moulds. The metals they use in the die casting process are non-ferrous, such as zinc, aluminum, copper, magnesium, as well as pewter and lead. They also make use of other tin-based alloys for die casting. There are two machines being used in the die casting process, namely the hot and cold chamber machines. Whether one is used instead of the other depends on the metals being casted. The equipment used in casting these metal dies are very expensive and count for major capital costs which limits the orders to high volumes.

What is Die Casting?

The making of parts for die castings is quite simple and involves only four steps which are what helps to keep the incremental costs per item very low. This makes it especially suited for large volume orders of small to moderate-sized castings. This is the reason why the die casting process tends to produce more castings as compared to other casting processes. Magnesium die casts, zinc die castings, and other metals used in the die casting process hold up well, which is why you will notice that die castings can be distinguished by their excellent surface finish as well as dimensional consistency. In magnesium die castings or other kinds metals used for die castings there are two variants from which you can choose from. One of them is pore-free die casting to help eliminate defects in gas porosity and they also make use of injection die casting variant which is especially useful in zinc castings so they can reduce scrap which can increase yield.

Different Metal Alloys for Different Uses

There are quite a number of metals being utilized in the die casting process. There is zinc, pewter, and magnesium. Each of these metals will have its own special use and purpose. If you want to talk about automobiles then you will want to learn about magnesium die castings. What makes magnesium die castings so popular on cars is the very structure of the metal itself. You see, magnesium is the lightest structural material you can find as it only weighs 1.8g/cm3. Magnesium is also the 8th most abundant element which you can find in the earth's crust which means there is no shortage of magnesium to be used. You can find this metal naturally occurring in Dolomite, Magnetite, Carnalite, and Chloride. You may wonder where magnesium is found and surprisingly enough, it can be found in sea water, brine, and other magnesium-bearing minerals which mean you get close to unlimited reserves of magnesium.

Advantages of Magnesium

So just why is magnesium such in high demand you may wonder. Granted it is available in nearly unlimited numbers seeing as they mined 350,000 metric tons in the year 1990 and 500,000 metric tons in the year 2005. However, there are other reasons for the increase in the production of magnesium die castings. For one, it is the lightest of all structural materials being 75% lighter than steel and 35% lighter than aluminum. Aside from the fact that it is lightweight, what makes parts made from magnesium die castings perfect for cars and other vehicles is they are very resistant to high impact. A lot of people put great stock in its high weight to strength ratio. Magnesium die castings have been discovered to have the capability of being cast into net shapes aside from having excellent dimensional stability and repeatability. Magnesium die castings are also 100% recyclable, which is why a lot of die-casting companies often use these in production.

How do You Choose an Alloy?

There are many types of magnesium alloys you can choose from. The selection is usually based on the environment where the part will function and the performance requirements of the components. For instance, the AZ791D alloy is most commonly used for die castings that involve very high pressure. This is the type of alloy that is most commonly used for parts used in power-trains and other mechanical components where the toughness of the metal is considered more important than any deformation capabilities. The next alloy utilized in die castings is the AM60B which is commonly used in producing automotive die castings which involve making safety components including a car's instrument panel and seat frames. This type of allow gives you excellent ductility. It also has one of the best energy absorbent properties plus it has a lot of strength and cast ability too. Another type of alloy you may be interested in is the AM50 which has lower aluminum content than the AM60 and has even more ductility to offer. Though it does have a slightly reduced strength and the casting ability is also slightly reduced. This alloy is typically used in procedures where the demands for elongation is beyond that of what the AM60 can offer.

Modernization And Competition Among Precision Die Casting Companies

Die casting is a procedure wherein melted metal is poured into molds made from steel to form new objects. These molds are commonly known as dies. They are specifically made to produce intricately detailed parts that require minor or zero finishing touches at all after fabrication. One great advantage is that die casts can be re-used numerous times for the reason that the temperature of the melted metal is not adequate to have an effect on or enough to deform the steel cast. Products that are made are usually lightweight and they are mainly used for automobiles or aircraft. In the industrial setting, precision die casting companies such as Dynacast abound and they supply materials and components for a variety of industries involved in manufacturing and construction.

Precision Die Casting Companies in Various Industries

For auto parts, die casting has existed nearly as long as the vehicle manufacturing industry has existed. These days, precision die casting companies are very innovative, spending a lot of resources in research and development. They are now customer oriented, making sure the customers' demands are met and are now facilitating changes to improve systems and adapt to world class methods. Each company seeks to exceed their customers' expectations including costs and delivery requirement to ensure their survival in the industry. Precision die casting companies including Dynacast grow with bigger plants and facilities to produce more and simply to outdo the competitor. This setting is actually beneficial for the end customers because prices tend to go down and more options or suppliers are available to choose from.

Competition Makes Room for Improvement

Die casting has come a long way since its conception. Due to tight competition, die casting companies have come a long way since. Materials used are nothing like the ones that were used from years back, and alloys are now the main component in almost every process, with aluminum die casting topping the list. This has become so widely used for a number of reasons. Aluminum casting involves liquid aluminum alloys pressurized into molds. Automotive and airplanes parts have diverted into this material mainly because it's lightweight and more durable as compared to other metals. The best thing about it is that die-casts are 100% recyclable and can be molded into new products and still come up with fine finish. The availability of this material also makes it an ideal choice for companies. Although it is more expensive compared to other metal die casting, it is still widely used because its advantages outweigh the costs of production. Without a doubt, aluminum is the most preferred material for die casting companies.

Working in Precision Die Casting Companies

Highly skilled professionals are in demand and companies such as Dynacast invest in them by providing further training to develop their aluminum die casting skills. This includes giving employees the appropriate training on die cast design and manufacturing. In designing, there are two categories - temporary mold and permanent mold. For die casting there are four sub-types, first is permanent casting - this is made from steel or iron. Second is sand casting - this is one of the oldest methods and used for making sand molds. Third is plaster casting which is also known as the baking method. Fourth is shell casting which is used for accurate dimensions. All of these need to be learned by employees in order to ensure quality and accuracy in a company's daily operations.

Examples Of Zinc Die Casting Companies

Zinc is a very popular alloy used in die casting. Through the process of die casting, parts are created with very high levels of accuracy. Zinc die casting companies focus either on creating die casts for you, or on actually producing the casts that come out of the die. Let's take a look at some of the best known zinc die casting companies. This way, should you ever need to have a zinc die cast produced, you will know where to go and what you can expect from the company.

A&B Die Casting

A&B Die Casting is well renowned international companies. This is one of the zinc die casting companies that also provides aluminum die casts. Their customer database is truly global. There specialization is mainly on medium to low volume solutions, while always keeping an eye on the highest levels of quality. A&B Die Casting pride themselves on making products with the highest levels of precision. Best of all, their prices are fair and very competitive compared to other companies.

Dynacast

Dynacast prides itself on its excellent reputation. It is said to be one of the world's leading zinc die casting companies. They have a huge customer database spanning across the globe. Besides zinc, they also offer aluminum and magnesium die casting solutions. One of the greatest things about this company is that they have such a good reputation that they have to work extra hard to make sure their customer satisfaction stays as high as what it is now. This truly is a company you can trust.

Premier Die Casting

Premier Die Casting has been operating for over 65 years. They pride themselves on being one of the zinc die casting companies that has always created casts and tools of the highest levels of quality. Besides zinc die casting, they are also experts in metal finishing as well as CNC machining. The processes and machinery they use are truly state of the art. Besides zinc, they are also specialists in aluminum die casts and their staff is a team of highly trained engineers and production operatives. They know how to create your parts the right way through high pressure die casting every time. The quality of Premier Die Casting is world renowned and their prices are incredibly competitive.

Del Mar Industries

Del Mar Industries is based in Gardena, Ca. They make sure their casts are all the highest possible standards. They have been operating in the industry for over 125 years, making them one of the oldest zinc die casting companies in the world. Having been around for so long, their customer database is unrivaled, with many multi-national companies working with Del Mar Industry in the production of their parts. They have also received awards on both national and international level. This is because their die casting expertise and their engineering design capabilities are some of the best in the world.

PMS Die Casting

PMS Die Casting is based in Europe, but has a global reach. One of the things that makes this company stand out from other zinc die casting companies is that it is a cooperative. This means that it is 100% owned by its employees. They make sure that they are innovative in their designs, that they use the highest levels of technology and that they employ future and fluid thinking at all times. Their quality is top of the range at all stages of the manufacturing process. This includes the design, the most critical part of the entire process, but also the engineering and the finishing. PMS Die Casting is always looking for new ways to become better. They want to achieve full excellence, not just in their products, but also in their reputation and the service they provide to their customers.

Kinetic Die Casting

Kinetic Die Casting focuses mainly on zinc die casts. They also use aluminum in making their parts. Just like many other zinc die casting companies, Kinetic Die Casting uses Zamak as their alloy. This is one of the most trusted types of alloys in the Zinc Aluminum (ZA) family.

Empire Die Casting

Empire Die Casting prides itself on being a no-nonsense, straight talking company. Their goal is to make sure their customers' expectations are not just met, but exceeded. Everybody who works for Empire Die Casting feels responsible for the end product, whether that be an aluminum or a zinc die cast. They want to make sure that their customers get the best, whether this means totally redesigning something or simply checking it and checking it again. And again. They focus on attracting new customers just as much as they focus on retaining their existing customers. They believe their actions speak a lot louder than their words.