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Introduction

The earliest examples of die casting by pressure injection - as opposed to casting by gravity pressure - occurred in the mid-1800s. A patent was awarded to Sturges in 1849 for the first manually operated machine for casting printing type. The process was limited to printer's type for the next 20 years, but development of other shapes began to increase toward the end of the century. By 1892, commercial applications included parts for phonographs and cash registers, and mass production of many types of parts began in the early 1900s.

The first die casting alloys were various compositions of tin and lead, but their use declined with the introduction of zinc and aluminum alloys in 1914. Magnesium and copper alloys quickly followed, and by the 1930s, many of the modern alloys still in use today became available.

The earliest examples of die casting by pressure injection - as opposed to casting by gravity pressure - occurred in the mid-1800s. A patent was awarded to Sturges in 1849 for the first manually operated machine for casting printing type. The process was limited to printer's type for the next 20 years, but development of other shapes began to increase toward the end of the century. By 1892, commercial applications included parts for phonographs and cash registers, and mass production of many types of parts began in the early 1900s.

The first die casting alloys were various compositions of tin and lead, but their use declined with the introduction of zinc and aluminum alloys in 1914. Magnesium and copper alloys quickly followed, and by the 1930s, many of the modern alloys still in use today became available.

The die casting process has evolved from the original low-pressure injection method to techniques including high-pressure casting - at forces exceeding 4500 pounds per square inch - squeeze casting and semi-solid die casting. These modern processes are capable of producing high integrity, near net-shape castings with excellent surface finishes.

Refinements continue in both the alloys used in die casting and the process itself, expanding die casting applications into almost every known market. Once limited to simple lead type, today's die casters can produce castings in a variety of sizes, shapes and wall thicknesses that are strong, durable and dimensionally precise.
A magnesium seat pan shows how complex, lightweight die cast components can improve production by replacing multiple pieces.

Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Parts have long service life and may be designed to complement the visual appeal of the surrounding part. Designers can gain a number of advantages and benefits by specifying die cast parts.
High-speed production - Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.
Dimensional accuracy and stability - Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant.
Strength and weight - Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
Multiple finishing techniques - Die cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.
Simplified Assembly - Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.

Die casting is one of the fastest and most cost-effective methods for producing a wide range of components. However, to achieve maximum benefits from this process, it is critical that designers collaborate with the die caster at an early stage of the product design and development. Consulting with the die caster during the design phase will help resolve issues affecting tooling and production, while identifying the various trade-offs that could affect overall costs.
For instance, parts having external undercuts or projections on sidewalls often require dies with slides. Slides increase the cost of the tooling, but may result in reduced metal use, uniform casting wall thickness or other advantages. These savings may offset the cost of tooling, depending upon the production quantities, providing overall economies.
Many sources are available for information on die casting design, including textbooks, technical papers, trade journals and professional associations. While this section is not intended to provide a comprehensive review of all the factors involving die casting design, it will highlight some of the primary considerations. Additional sources of information are listed in the "Resources" section of this brochure.

- A -
Automation -- Industry term commonly used to describe the mechanization of various aspects of the die casting process.
- B -
Biscuit -- Excess of ladled metal remaining in the shot sleeve of a cold chamber die casting machine. It is part of the cast shot and is removed from the die with the casting.
Blister -- A surface bubble caused by gas expansion (usually from heating) which was trapped within the die casting or beneath the plating.
Blow holes -- Voids or pores which may occur due to entrapped gas or shrinkage during solidification, usually evident in heavy sections (see porosity).
- C -
Cavity -- The recess or impressions in a die in which the casting is formed.
Cold chamber machine -- A type of casting machine in which the metal injection mechanism is not submerged in molten metal.
Checking -- Fine cracks on the surface of a die which produce corresponding raised veins on die castings. Checking is caused by repeated heating of the die surface by injected molten alloys.
Creep -- Plastic deformation of metals held for long periods at stresses lower than yield strength.
- D -
Die lubricant -- Liquid formulations applied to the die to facilitate casting release and prevent soldering.
Dimensional stability -- Ability of a component to retain its shape and size over a long period in service.
Dowel pin -- A guide pin which assures registry between cavities in two die halves.
Draft -- The taper given to walls, cores and other parts of the die cavity to permit easy ejection of the casting.
- E -
Ejector marks -- Marks left on castings by ejector pins.
Ejector plate -- A plate to which ejector pins are attached and which actuates them.
- F -
Fillet -- Curved junction of two surfaces, e.g., walls which would meet at a sharp angle.
Flash -- A thin web or fin of metal on a casting which occurs at die partings, vents and around moveable cores. This excess metal is due to working and operating clearances in a die.
- G -
Gate -- Passage for molten metal which connects runner with die cavity. Also, the entire ejected content of a die, including castings, gates, runners, sprue (or biscuit) and flash.
Gooseneck -- Spout connecting a metal pot or chamber with a nozzle or sprue hole in the die and containing a passage through which molten metal is forced on its way to the die. It is the metal injection mechanism in a hot chamber type of die casting machine.
Growth -- Expansion of a casting as a result of aging or of intergranular corrosion, or both.
- H -
Heat checking -- (see checking)
Hot chamber machines -- Die casting machines which have the plunger, gooseneck (metal pressure chamber) immersed in molten metal in the holding furnace.
Hot short -- Term used to describe an alloy which is brittle or lacks strength at elevated temperatures.
- I -
Impact strength -- Ability to resist shock, as measured by a suitable testing machine.
Impression -- Cavity in a die. Also, the mark or recess left by a ball, or penetrator of a hardness tester.
Ingot -- Metal or alloy cast in a convenient shape for storage, shipping and remelting.
Injection -- The process of forcing molten metal into a die.
Insert -- A piece of material, usually metal, which is placed in a die before each shot. When molten metal is cast around it, it becomes an integral part of the die casting.
Intergranular corrosion -- A type of corrosion which preferentially attacks grain boundaries of metals or alloys, resulting in deep penetration.
- J -
None
- K -
FNone
- L -
Loose piece, knockout -- A type of core (which forms undercuts) which is positioned in, but not fastened to a die. It is so arranged as to be ejected with the casting from which it is removed. It is used repeatedly for the same purpose.
- M -
Metal saver -- Core used primarily to reduce amount of metal in a casting and to avoid sections of excessive thickness.
Multiple cavity die -- A die having more than one duplicate impression.
- N -
Nozzle -- Outlet end of a gooseneck or the tubular fitting which joins the gooseneck to the sprue hole.
- O -
Overflow-well -- A recess in a die connected to a die cavity by a gate to assist in proper venting.
- P -
Parting line -- A mark left on a die casting where the die halves meet; also, the mating surface of the cover and ejector portions of the die.
Plunger -- Ram or piston which forces molten metal into a die.
Port -- Opening through which molten metal enters the injection cylinder.
Porosity -- Voids or pores resulting from trapped gas, or shrinkage during solidification.
Process control -- Where parameters of a process are studied and correctly applied in the manufacturing process to produce high quality parts.
- Q -
None
- R -
Runner -- Die passage connecting sprue or plunger holes of a die to the gate where molten metal enters the cavity or cavities.
- S -
Shot -- The segment of the casting cycle in which molten metal is forced into the die.
Shrinkage, solidification -- Dimensional reduction that accompanies the freezing (solidification) of metal passing from the molten to the solid state.
Shrink mark -- A surface depression which sometimes occurs next to a heavy section that cools more slowly than adjacent areas.
Slide -- The portion of the die arranged to move parallel to die parting. The inner end forms a part of the die cavity wall that involves one or more undercuts and sometimes includes a core or cores.
Soldering -- Adherence of molten metal to portions of the die.
Split gate -- A gate of castings having the sprue or plunger axis in the die parting.
Sprue -- Metal that fills the conical passage (sprue hole) which connects the nozzle with runners.
Sprue pin -- A tapered pin with a rounded end projecting into a sprue hole and acting as a core which deflects metal and aids in the removal of the sprue.
Stability, dimensional -- (see dimensional stability)
- T -
Toggle -- Linkage employed to mechanically multiply pressure when locking the dies of a casting machine.
Trim die -- A die for shearing or shaving flash from a die casting.
- U -
Unit die -- A die interchangeable with others in a common holder.
Undercut -- Recess in the side wall or cored hole of a casting disposed so that a slide or special form of core (such as a knockout) is required to permit ejection of the casting from the die.
- V -
Vent -- Narrow passage at the die parting which permits air to escape from the die cavity as it is filled with molten metal.
Void -- A large pore or hole within the wall of a casting usually caused by entrapped gas. A blow hole.
- W -
Waterline -- A tube or passage through which water is circulated to cool a casting die.
- X -
None
- Y -
None
- Z -
None