Part 2: Aluminum Die Casting vs. Other Casting Processes

The great part about this industry is that there are a number of valuable resources available; sometimes the hard part is finding them.  Last year I created a General Casting Design Data Sheet in hopes of having a single reference point for the properties and tooling specs for seven of the most widely used casting processes.

While this was helpful to a number of people, there are just some details that can’t be explained in a spreadsheet.  So I decided to take it a bit further.

I’ve listed quick comparisons between Die Casting and other processes for anyone who’s looking to evaluate a new project.

  • Die casting vs. plastic molding – Die casting produces stronger parts with closer tolerances that have greater stability and durability.  Die cast parts have greater resistance to temperature extremes and superior electrical properties.
  • Die casting vs. sand casting – Die casting produces parts with thinner walls, closer dimensional limits and smoother surfaces.  Production is faster and labor costs per casting are lower.  Finishing costs are also less for die casting, however the tooling is higher in die casting than sand casting.

  • Die casting vs. permanent mold – Die casting offers the same advantages versus permanent molding as it does compared with sand casting. However permanent mold tooling is much more expensive than sand casting but lower than die casting.
  • Die casting vs. forging – Die casting produces more complex shapes with closer tolerances, thinner walls and lower finishing costs.  Cast coring holes are not available with forging.
  • Die casting vs. stamping – Die casting produces complex shapes with variations possible in section thickness.  One casting may replace several stampings and can provide added features on the part at no additional unit cost, resulting in reduced assembly time.
  • Die casting vs. screw machine products – Die casting produces shapes that are difficult or impossible from bar or tubular stock, while maintaining tolerances without tooling adjustments.  Die casting requires fewer operations and reduces waste and scrap.

Premier utilizes state of the art equipment in manufacturing high pressure aluminum die castings such as Kawasaki robots, VisiTrak process monitoring systems, Mokon die temperature control systems, vacuum die casting, and a central lubrication system for the die spray.

If you have any parts you would like Premier to review, please send your drawings or files to lc@diecasting.com By Leonard Cordaro, President of Premier Engineered Products

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