Die Casting:

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Aluminum alloys are more utilized in die casting than alloys of any metal. In USA alone 2.5 billion dollars worth aluminum alloy die castings are manufactured every year. Die castings are suitable for production of smaller parts. But when expensive manufacturing equipment is used the castings weigh 5kg-50kg. Cost effectiveness can be obtained only by large scale production. With die casting it is possible to have close tolerance and fine finishing surface. Die castings are manufactured by injecting melted metal into metal molds under considerable pressure. Quick injecting and quick solidification under high pressure make a fine grain surface, which leads to having best wear and fatigue properties. Aluminum die castings are generally not given heat treatment, so they cannot be welded.

Permanent die casting: