Die casting is a process like injection molding in plastics but with molten metal. In the die casting process, a machine holds a mold that is closed with many tons of force and molten metal is injected.
In die casting, tool design and gravity are key for us to be able to create gates and dumps to control porosity. Each time the machine cycles, parts drop out and the cycle begins again. The process is suited for smaller parts under 10 pounds with the ideal being between 0 and 2 pounds.
Vulcan has several different master tools set up so that we can mold both low and quantities in the most cost effective way possible. Many parts that we run number between 50 and 500 pieces. We have multiple master dies to help find a solution that fits your needs.
Die casting is best suited for parts that contain antimony to improve the flow of the metal into the mold. The ideal antimony blend is 2 or 3 percent.
Vulcan can also die cast lead tin blends of metal. In die casting, a typical tolerance will be +/-.010″ to mean. In some cases, parts and specific dimensions can be tighter. Please contact us to discuss your specific needs and alloy options.