Northwest Die Casting
      Minority Owned Die Cast Company
9510 SW Tualatin Rd. Tualatin, Oregon 97062
Tel: 503.885.8200 | sales@nwdiecasting.com

           ISO 9001:2008 Certified Company

 

         High Quality American Die Cast Parts

        "To compete in a world wide market we pride ourselves on
         providing high quality die castings and excellent customer
         service at very competitive prices."
         

          Let us quote your next project!
                      


      
 
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Northwest Die Casting LLC, Die Castings, Tualatin, OR
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What is Die Casting?
Die Casting is a metal forming method for manufacturing engineered metal parts by injecting molten metal under high pressure into a steel mold, which is also known as a die. Following the metal injection the die casting machine will clamp down onto the mold, forming the die casting part which quickly solidifies. Molds called Dies are very durable with an great ability to produce complicated shapes with an impressive degree of accuracy and repeatability. Die casting parts are typified by their sharply defined, smooth or textured surfaces and dimensional consistency.

Producing parts using the die casting process is considered to be the most efficient way of converting raw material into a finished product. Die castings are best suited for mass production of small to medium sized castings, which is why they can be found in many of the commercial, industrial, and consumer products.
The majority of die castings are made from non-ferrous metals, such as aluminum, copper, lead, magnesium, pewter, tin, and zinc based alloys.. Little or no machining is required. A complete die casting cycle can vary from less than a second for small components to 2-3 minutes for larger components.


Die Casting is normally done using two different processes


In a cold chamber process, molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as aluminum and copper that alloy easily with Iron at  higher temperatures.


In a hot chamber process the pressure chamber is connected to the die cavity and immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures. Aluminum, zinc and copper alloys are the materials predominantly used in die-casting. Pure aluminum, however, is rarely cast due to high shrinkage and susceptibility to hot cracking.
  • Aluminum Alloy Parts have good corrosion resistance and mechanical properties, high thermal and electrical conductivity, as well as strength at high temperatures. Aluminum is often cast at a temperature of 650 C. It can be alloyed with silicon and copper. Silicon increases the melt fluidity, whereas copper increases hardness and reduces ductility. 
  • Zinc Alloy Parts are the easiest alloy to die cast. Zinc is economical for small die cast parts and has a low melting point. The casting is done at a fairly low temperature of 425 C so the part does not have to cool much before it can be ejected from the die. This, in combination with the fact that Zinc can be run using a hot chamber process allows for a fast fill, fast cooling.

Processes & Advantages of Die Casting

 

The process of die casting using pressure injection can be traced to mid 1800. The components that were used in the initial stages were tin and lead but their use tapered off with the introduction of alloys of zinc and alloys of aluminum. The process has evolved over the years from the low pressure injection techniques to the casting dies at pressures that can reach as high as 4500 psi. The processes are capable of creating high quality products that have excellent surface finishing.

 

The die casting process is an economical yet effective process of creating a broad range of shapes. It is considered superior to other manufacturing technique and is considered durable and aesthetic, merging seamlessly with the other parts of the machinery of which it is a component. Die casting has many advantages and primary among them is its ability to deliver complex shapes with high levels of tolerance than any other mass production methods. Identical castings can be mass produced in thousands before you are required to add any new die casting tools.

 

High pressure die casting is a manufacturing process in which the aluminum in its molten form is injected with a die casting machine under extreme force, speed and pressure into a steel die or mold to create parts of the desired shape and design. The rating of die casting machines is in clamping tons universally. This rating reflects the amount of pressure exerted on the die. The size of the machine ranges from 400 to 4000 tons.

 

There are many benefits of using die casting process over others. Die casting produces parts with thinner walls, closer limits of dimension and it is possible to speed up the process. Labor and finishing costs are the lowest with die casting. Complex shapes with closer tolerances can be easily achieved with this process. Unlike forging process, you can cast coring in products created through this process.


Shapes impossible to achieve from bar or tubular stock can be easily achieved with die casting. The number of operation processes is less, leading to lower wastage of materials.


Die casting is used when you need parts that are dimensionally stable and durable. They are heat resistant and maintain good tolerance levels which are crucial pre-requisites for any good machinery parts. They are stronger and lighter than parts made by other casting methods. They do not have parts that are welded or bolted together, thereby immensely enhancing their efficiency. Another advantage is the multiple finishing that you can achieve with die casting. The surfaces can either be smooth or textured providing ease of application and use.