Die casting has helped to revolutionise industries by allowing for the mass production of identical, intricate metal parts. Now a widely used process, it can still be complex to get to grips with – especially if you’re new to the method.
Here at Lupton and Place, we’ve been at the forefront of the die casting trade for many years and specialise in four types – aluminium, gravity, structural and pressure die casting. Unsure which one is right for your application? Here we take a closer look at each technique to help you identify the best solution.
Aluminium die casting
Aluminium die casting is a popular and cost-effective option thanks to its particularly high production rates.
Pros: aluminium is naturally lightweight and durable – it’s also a great conductor of electricity, all of which are frequently sought-after qualities for metal parts.
Aluminium die casting is a particularly great choice for environmentally conscious companies as this metal is fully recyclable, meaning pieces can be reused again and again.
Typically used for: the possibilities are endless but some of the typical uses include car and aircraft parts, medical equipment, DIY and gardening tools.
Gravity die casting
Gravity die casting was one the pioneering die casting processes. The metals used in this method are usually non-ferrous alloys – such as copper, zinc and aluminium and their resistance to corrosion and rust makes them ideal for parts that are going to be used outdoors.
Pros: gravity die casting can produce dense, high-quality castings with excellent mechanical attributes like strength and rigidity. Casts can be simple or highly intricate – there is no restriction. And multiple finishes are also available including smooth or textured.
Typically used for: ideal for the diverse and complex casting production of automotive equipment such as brake calipers, engine cylinder heads, pistons and engine blocks. Gravity die casting is also suitable for many other industries and can be used for everything from producing lighting components to kitchen equipment.
Pressure die casting
A fully automated process, pressure die casting is a quick, reliable, and cost-effective manufacturing method that ensures excellent repeatability and production quality. These machines can deliver light alloy parts with superior precision, along with exceptional uniformity and surface finish.
Pros: high pressure die casting technology can produce castings with extremely thin walls, helping to reduce weight. It is cost-effective for particularly high-volume production.
Typically used for: this process is frequently used for castings requiring tight tolerance and detailed geometry, as the extra pressure helps to push the metal into the intricate features of the mould. It is a widely used form of die casting and applications range from very simple pieces right through to the most demanding, such as aircraft parts.
Structural die casting
Structural die casting can be used across all manner of industries but is particularly favoured at the higher end of the automotive market and for aerospace, where the creation of extremely lightweight, high performance and precise pieces is crucial.
Pros: a structural diecasting machine uses real-time, closed-loop control, guaranteeing maximum casting integrity and quality. Components can be produced in aluminium alloy AlMg5Si2Mn, using a multi-stage vacuum – resulting in high strength parts suitable for structural applications without the need for heat-treatment.
Typically used for: structural die casting is extremely popular in the automotive industry and – with a surge in hybrid and electric cars – it provides a real opportunity to replace heavy steel elements with much thinner, lighter alternatives.
Still unsure about which one is right for you? No problem. Our team of experts are here to help and are always happy to talk through the different services we offer and find the right die casting solution for you and your project. Simply call us on 01282 422 361 or complete our online form and we will get back to you.