Die casting is a metal casting process characterized by the use of a mold cavity to apply high pressure to melted metal. Molds are usually machined with higher strength alloys, in a process somewhat similar to injection molding. Most die casting castings are iron-free, such as zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys and their alloys. Depending on the type of die casting, either a cold chamber die casting machine or a hot chamber die casting machine is required.
The cost of casting equipment and molds is high, so the die casting process is generally only used to mass-produce a large number of products. It is relatively easy to manufacture die-cast parts, which generally requires only four major steps and a low individual cost increment. Die casting is particularly suitable for manufacturing a large number of small and medium-sized castings, so die casting is one of the most widely used in various casting processes. Compared to other casting technologies, die casting has a flatter surface and a higher dimensional consistency.
On the basis of the traditional die casting process, several improved processes have been born, including the non-porous die casting process to reduce the casting defect exclusion porosity. Mainly used for processing zinc, which can reduce waste and increase the yield of direct injection process. There are also new die-casting processes such as precision and close die-casting technology and semi-solid die-casting invented by General Dynamics.