From casting industry is born, people alway explore casting part to meet the demand of their daily life. The oldest casting method is sand casting, which forming the metal casting part with simple sand molding tool, without tight tolerance and accurate dimension and uneven and tough surface. The casting technology is suitable for heavy weight bases with tough surface at low volume,such as iron casting parts, copper casting parts and some of tough aluminum casting parts. With the continuous improvement of die casting technology, innovative man create precise steel tools, with which, people can produce tight tolerance and accurate dimensional die casting parts. Like Aluminum casting dies and steel casting dies. Die casting vs sand casting: difference and comparison, The following let everyone know the detailed about it.
Die Casting VS Sand Casting
- Fast Casting vs Slower Casting
- Tight Tolerance vs Loose Tolerance
- Complex Mold Design vs Simple Sanding mold
- Smooth Surface Finish vs Tough Surface Finish
- Minimizing machining vs high volume cutting and turning
Die Casting Overview and Comparison To Sand Casting
What is Die Casting ?
Die casting is a metal casting process, which means forcing molten metal into a mold cavity under high pressure. Then cooling the die and solidifying the molten metal, forming the intended shape casting part. Certainly the mold cavity is created using two halves of hardened tooling steel dies which have been machined into shape. We start assembling the die on the right die casting machine, and align with the die. With the large hydraulic piston, pushing the melton metal into the high speed steel die and form the casting part. Everyone know that, most die castings are made from non-ferrous metals.
such as zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depends on the different metal casting, using the hot and cold chamber die casting machine, manufacturer will produce the die casting part with high precision and fine surface finish. Comparing with sand casting, which is a traditional and old type of casting process, offers tough surface and low precise casting parts.
Die Casting Vs Sand Casting
| Aspects | Die Casting | Sand Casting |
|---|---|---|
| Mold Material | Aluminum &Steel dies (permanent) | Sand molds (expendable) |
| Production Speed | Very fast (high-pressure injection) | Slower (natural flow injection, without any pressure) |
| Surface Finish | Smooth, precise (minimal post-machining) | Rough, may need post-processes. |
| Tolerances | Tight (ยฑ0.1 mm or better) | Looser (ยฑ1 mm or more) |
| Part Size | Small to medium (up to ~50 kg) | Very large (, heavy industrial machinery chassis and main frames, several tons possible) |
| Cost | High initial tooling, low per-unit cost and high automation production line. | Low tooling, higher per-unit labor cost, porosity on surface of casting part. |
| Metal Options | Limited (non-ferrous alloys preferred) | Almost any metal (including ferrous) |
| Mold Design | Complex and longer life tooling | Simple and lower life tooling |
The Different Applications For Die And Sand Casting
Die Casting Applications
These different size die casting parts have been used across many industries. Certainly miniature die casting parts require high precision and complex structural design. So engineer suggest that making precise casting dies and ensure providing high quality die casting components in high effective.
Automotive Industry
- Interior and Exterior Components : Handles And Lock setting and Security belt buckle, which blong to die casting components.
- Engine Housing And Trasmission Cases : Form these high strength structural large size components using precise high speed steel tools.
- Headlighting Housing, steering wheel and Airbag bases: These components are cast with different castable alloy material.
- Fuel filter, tube fittings and adjustable valves: These small size components can be cast with zinc alloys. with strong corrosion resistance, endure acid corrosion from gas.
- Suspension Chassis And Brake blade blocks: These iron cast components, like suspension chassis balances the car , howder the brake blades can brake the car when emergency happens.
Consumer Electronics Industry
Daily Mini Earphone Supporting Frames: Die casting manufacturer produces small size supporting frames depends on Anthropology structure, and comfort consumers, brings relax and enjoyment to consumer.
Wireless Charger Bases: Like these components, manufacturers choose aluminum die casings and zinc die castings, its features is to protect the electronic board and transfer overheat from the electrical components towards air and other substance, keep low temperature.
Watch Cases: With high precision die, die casting can create fine surface finish as cast part, then accept minimal cnc machining, and become exiquisite wathc cases.
Car key Case Covers: large volume car key case covers in mordern market are made of zinc alloys, passing post-process, and complete the process of car key case covers.
Aerospace & Defense Industry
Aircrafts and planes need large volume lightweight metal component so that reduce overweight of these aircrafts, and aim to the target of cost-efficiency of fuel and speed up the aircraft. So aluminum die castings and lightweight zinc die castings are best for aerospace and defenese industry.
HomeHold Hardware Industry
Handle, bases and frames for appliances, which are wear resistance, solid and flexible geometries. And easy to cast, with lower cost. Like homehold flood mixer, egg mixer, switch knob and display panels. These zinc die casting parts are eco-friendly and 100% recycled and sustainablity.
Furniture & Decoration Construction Industry
Die casting manufacturers cast handles, hinks and Smart lock bases with different alloy metal, Any aesthetic appeal shape and a good structural design, die casting can accept and create the intended metal component. Sometimes die casting can create some decorative trims for home decoration.
Sand Casting Applications
Heavy Machinery & Equipment
Main Frame And Chassis of Heavy Machinery : These heavy weight components is not need of precise dimensions and tight tolerance, and hold the steady of machine. This ensures the heavy machinery and equipment run in stable. With sand casting technology, manufacturer can process mass components.
Rail & Marine
These large sizes products require forming the intended shape and meet the specific requirements of these components.
Art & Sculptures
With stand, people can make the simple sand mold, and inject imagination sculptures and only need a low tolerance dimensions. People can inject aluminum, copper, gold, silver into the sand mold, make different material artical sculptures.
