Q: What is the die casting process? A: The die casting process involves injecting a molten alloy under high pressure into a steel mold or die, where it cools and solidifies. Afterward, the die is opened, and the casting is removed.
Q: What materials can be used in die casting? A: Die castings are typically made from non-ferrous metal alloys like zinc, copper, aluminum, and magnesium. Lead, pewter, and tin alloys are also used occasionally.
Q: What design input is needed for die casting? A: For simple products, 2D files with basic dimensions, tolerances, and weight are usually sufficient. More complex parts require 3D files. Various file formats are acceptable, with step files commonly used.
Q: Where can I find die casting manufacturers in China? A: Die casting factories can be found across China, influenced by local environmental regulations. Working with an experienced China sourcing agent is recommended for locating suppliers and managing production efficiently.
Q: How much does tooling cost in die casting? A: Tooling costs vary widely, ranging from a few hundred dollars for small, simple tools to hundreds of thousands for larger, complex tools.
Q: How long does tooling last in die casting? A: Tooling lifespan depends on factors like cost, materials, injection material, and part structure. While some tools can last up to 100,000 cycles, a realistic range is 60,000 to 70,000 cycles.
Q: What is the average lead time for tooling in die casting? A: The average lead time for tooling typically ranges from 20 to 60 days, depending on specifications, complexity, and size.
Q: What does the tooling process involve in die casting? A: Tooling includes machining or electrical discharge machining (EDM), heat treatment, and adding surface textures. Specific surface finishes or textures may extend the tooling lead time.
Q: What are the pros and cons of die casting? Pros:
- Consistent measurements.
- Ability to create high-complexity parts.
- Quick production rates.
- Low cost per unit.
Cons:
- High tooling cost.
- Potential for warpage and shrinkage.
- Surface finish may not match machined parts.
Q: What are the known challenges in the die casting process? A: Challenges include handling hollow parts, which might require investment casting. Issues related to dimensions, surface finish, and porosity can arise, depending on post-treatment and final finish requirements.