Among all the techniques of metal casting and metalworking, none is more popular than die casting to form parts. The reason is due to the incredible versatility as well as accuracy, repeatability, and moderate cost of the high-pressure die casting process.

You can find die-casted parts, which range from doorknobs to engine housing, almost everywhere. What are the advantages of high-pressure die casting with other manufacturing techniques that have become widely used? You will find the answer here in this article.

What is High-Pressure Die Casting?

The high-pressure die casting process utilizes speed and high-intensity pressure to create accurate and cost-effective metal casings. It has a reputation for reliability and most manufacturers swear that it is an ideal option for creating identical metal parts in huge quantities.

Compared with gravity die casting, where the molten metal is poured into the mold from an upright position, in pressure die casting, the material is directly injected into the steel dies. The process is automated, hence, you can expect quick cycle time.

Amongst the industries that benefit from its advantages, electric, kitchenware, hardware, and aerospace are its most common applications.

Comparison With Other Production Processes

Compared with other production techniques, high-pressure die casting has its own set of advantages.

Plastic Injection Molding

If you compare high-pressure die casting with plastic injection molding, you will find the former to be stronger, stiffer, more heat-resistant, more stable, and more stable than plastics based on its properties to cost analysis.

The die-casted parts have more permanency under load compared to plastic. It is also completely resistant to the elements like ultra-violet rays, stress-cracking, and weathering. Another advantage of die casting over plastic molding is its faster manufacturing cycle.

Plastics, on the other hand, are cheaper in terms of cost per unit. It also has inherent color and finishing is not required anymore. Plus, they are good insulators for electricity.

Sand Casting

A close relative of die casting, sand casting is a process that requires more machining. Die casting can be made with thinner walls and holes cored to the size, while sand casting cannot.

The process can also produce thousands of parts without changing the die and it does not need new cores between each casting. The die-casted parts have a smooth finish so no additional labor is needed.

Sand casting, on the other hand, can use ferrous and non-ferrous alloys which are not suitable for die casting. It can also accommodate larger size and low volume production. Tooling cost is also lesser.

Forging

High pressure die casting can produce more complex parts and shapes, which are not forgeable. It can also make parts with thinner walls and coring which are not feasible with forging.

Forging, on the other hand, is stronger and denser than die-casted parts. It can also produce a part in ferrous and non-ferrous metals.

Stamping

Compared to stamping, die casting requires fewer tools and assembly. One die can replace several parts in stamping and can produce parts within its dimensional limitations.

Meanwhile, stamping can make parts that are not possible with die casting. These parts are produced rapidly and can be more lightweight than casted parts.