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.
Die Casting vs. Forging
There is considerable debate about which manufacturing process is better, die casting or forging. In reality, there is no “one size fits all” answer because there are advantages to both. Here is a quick overview of the differences between die casting and forging to help you decide which process is best for your application.
Die Casting
Die casting is a manufacturing process that uses high pressure to force molten metal into a mold cavity with incredible force and accuracy. This process produces parts that have a consistently higher surface quality than what can be produced with forging, especially when the small details of the design are critical. Die casting is also a more efficient way to manufacture parts because they can be quickly designed, produced and machined with minimal scrap and labor.
Forging
Forging, on the other hand, is a process in which metal is hammered, pressed or rolled under high temperature and pressure to transform it into the desired shape. Forging is extremely strong and has the unique capability to produce complex shapes and precision details that are difficult to otherwise achieve. In addition, the proof of strength for forgings is typically much higher than what can be achieved with die casting.
Which Process to Use
In general, die casting is the preferred process when parts require low- to medium-volume production, have intricate shapes and require precise details to be replicated. On the other hand, forging is more cost-effective and less expensive for high-volume production and parts with complex shapes and low- to medium-volume production but that require higher proof strength.
Conclusion
When deciding which process to use for your parts, it is important to weigh the advantages and disadvantages of both die casting and forging before deciding on the optimal manufacturing process for your application. Both processes are capable of producing high-quality, precision parts with detailed designs but it is up to you to determine which one is the best fit for your needs.
