What is high pressure die casting?
High pressure die casting is the process of injecting molten metal into a die tool cavity at high speed and force to realise the desired product shape and form.
The raw material used for the process is usually a casting grade of zinc, aluminium or magnesium, and the size of the products can vary from very small to very large, depending on tool and machine size.
Why high pressure die casting?
Die castings give designers the ability to achieve strong, consistent, intricate shapes, tight dimensional accuracy using space and weight saving materials.
For some requirements, the cost of the design and manufacture of the high pressure die casting tooling can be significant, however the piece part component cost will often be lower than other forms of manufacture. Tool life expectancy of 1,000,000 shots would not be unreasonable for high pressure zinc tooling, meaning the higher cost of the tooling could be offset by lower piece part costs for the life of the project. Depending on the design of the product being cast and the material used the tool life expectancy of aluminium is much lower at around 100,000 shots.
Your requirements would be suited to high pressure die casting if some or all of the following criteria can be applied to your needs.
- Lower piece part cost and weight.
- Medium to high volume
- Precision accuracy in shape and form.
- Thinner wall sections.
- Parts require machining.
- Parts require a decorative or protective coatings / finish
Zinc
Zinc Die Casting
The zinc die casting process with close tolerance components is one of the most precise three-dimensional mass production techniques available, and the fastest way between raw material and finish product, add the benefit of fast cycle times, machinability and its ability to accept a range of various surface treatments and finishes makes it a material of choice for many of our customers.
Commonly referred to as Hot Chamber casting, zinc die casting has a lower melting point than other non-ferrous alloys such as aluminium, is fully recyclable, easily machined and ideal for coating applications such as powder coating or chrome plating.
Benefits of zinc die casting
- Precision
- Performance
- Price
- Longer tool life
Components of the hot chamber die casting machine:
Capability
BSC has the machine size and knowhow to manufacture components in zinc as small as your finger nail or as large as the font on the bar at your local pub (seriously, we probably made it!).
In principle the greater the locking force, the bigger the casting, on site we have both conventional and multi-slide high pressure zinc casting machines ranging from 6 tonnes of locking force up to 400 tonnes.
We also cast in numerous different casting grades of zinc to suit the component needs and application, meaning we more than likely have a zinc casting solution for you. The correct zinc alloy choices will depend on a range of factors, from the size of the casting, extremes of environmental exposure, and the expected mechanical stresses of the final application.
View Zinc Material Data Sheets
Aluminium
Aluminium Die Casting
The aluminium die casting process allows customers to reduce the weight of components over other non-ferrous die cast alloys whilst maintaining performance. Commonly referred to as Cold Chamber casting, Aluminium die casting has a higher melting point ensuring components are more heat resistant. Aluminium parts also easily machinable and have high corrosion resistance.
Benefits
- Reduced weight
- Lower raw material prices
- Easier to machine
- Recyclable
Components of the cold chamber die casting machine:
Capability
BSC has the machine size and know-how to cast parts in aluminium ranging from small to large. Our machine sizes for cold chamber aluminium casting range from 250 tonnes of locking pressure up to 900 tonnes. A larger part could be up to 11kg in weight, such as the tread plate of an escalator.
With our extensive knowledge of aluminium alloys and how they interact with the full range of surface coatings, we can advise during the design stage to identify which alloy is optimal – and most cost-effective – for your particular application. So whether you require the traditional LM-24 or the extra corrosion resistance and ductility of LM-6, you end up with the right casting for you.
View Aluminium Material Data Sheets
Zinc or Aluminium
Choosing between zinc and aluminium for your high pressure die cast component can be daunting. We can help you choose a specific metal grade that suits your needs during the early stages of your project, but please see below our guide to the differences between the two main casting alloys as a starting point.
Benefit
Zinc Alloys
Aluminium
Strength
Benefit
Zinc Alloys
Aluminium
Forming
TECHNICAL NOTES
Both materials , depending on the alloy can be formed, zinc is more malleable of the two and is often swaged or spin riveted to hold casings together.
Benefit
Zinc Alloys
Aluminium
Weight
Saving
Saving
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Plating
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Complexity
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Powder
Coating
Coating
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Casting
Complexity
Complexity
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Wet
Painting
Painting
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Thin Wall
Sections
Sections
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Tool
Life
Life
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Precision
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Machine
Cycle Times
Cycle Times
TECHNICAL NOTES
Benefit
Zinc Alloys
Aluminium
Machinability
TECHNICAL NOTES
Providing a better cast and a better finish.
All raw material is sourced in the UK.
T: 01922 710 070
E: info@bscdiecasting.co.uk
BSC Die Casting & Finishing Ltd
Fryers Close, Walsall,
West Midlands, WS3 2XQ
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