Die casting
Die casting, or high-pressure die casting (HPDC), is a process in which molten metal is injected under high pressure into a reusable steel die. It produces thin-walled, dimensionally accurate parts with a good surface finish and is the standard process for aluminium housings and covers in large series.
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Typical parts
- Housings for gearboxes, pumps and electric motors
- Covers and lids
- Brackets and mounting parts
- Heat sinks and electronics enclosures
- Hydraulic and pneumatic component bodies
Quantities
- High annual quantities
- Stable part design
Inspection
- Alloy composition by spectrometer
- Full first article, often on CMM
- Porosity by X-ray or sectioning if specified
- Leak test for housings that must be tight
Documents
- EN 10204 3.1 certificate
- Dimensional report
- PPAP or VDA 2 sampling where possible
How die casting works
In aluminium die casting, molten metal is ladled into a shot sleeve and a piston forces it into the die cavity at high speed and pressure. The metal solidifies within seconds, the die opens and the casting is ejected.
After casting, the gating system and overflows are trimmed off, usually in a trim press. Parts are then deburred, shot blasted and machined as required.
Quality checks and documents for die castings
Alloy composition is checked by spectrometer. First articles are measured in full, often on a coordinate measuring machine. Porosity is checked by X-ray or by sectioning where the drawing specifies it, and housings are leak tested when they must be tight.
Standard documents are a material certificate to EN 10204 3.1 and a dimensional report. For automotive projects, sampling can follow PPAP or VDA 2 where the manufacturer is set up for it. More on the quality page.
Materials for die casting
Aluminium
EN 1706
- EN AC-AlSi9Cu3(Fe) (46000)
- EN AC-AlSi12(Fe) (44300)
- EN AC-AlSi10Mg(Fe) (43400)
There is no fixed size or weight limit. Send us your drawing and we will define the right production route for the part and confirm feasibility. Dimensional tolerances are agreed on the drawing, usually with reference to ISO 8062-3.
Is this the right process?
When die casting is the right choice
- Annual quantities are high and the part design is stable
- The part is aluminium and has thin walls, ribs or many details
- A good as-cast surface and repeatable dimensions reduce machining
When another process is better
- Low or uncertain quantities: sand casting or permanent mould casting need far less tooling investment
- Parts that must be solution heat treated (T6) or welded: permanent mould casting gives denser castings
- Iron or steel parts: die casting is limited to non-ferrous alloys; use sand casting or investment casting
Related pages
- CNC machiningCNC turned, milled and ground parts, EDM, laser and waterjet cut parts from machine shops in Türkiye, from prototypes to series, with dimensional reports.
- Secondary operationsHeat treatment, galvanising, powder coating, KTL e-coating, painting and assembly for cast, forged and machined parts, managed by QProcess in the same order.
- Commercial vehicles and automotiveHubs, brackets, die cast housings, shafts and turned parts for commercial vehicle, trailer and automotive tier suppliers and the aftermarket, from Türkiye.
- Machinery and equipmentMachine bases, housings, shafts, gear blanks, guides and plastic wear parts for machinery and equipment manufacturers, produced by manufacturers in Türkiye.
- Other industriesCast, forged, machined and plastic parts for pumps and valves, hydraulics, rail, material handling, industrial automation, robotics and marine equipment.
Frequently asked questions
From which quantity is die casting economical?
Die casting needs a steel die, which is a significant one-off investment. It pays off when the annual quantity is high enough to spread the die cost. For lower quantities, permanent mould or sand casting is often cheaper per finished part. We compare the options when we quote.
Can die castings be heat treated or welded?
Standard die castings contain small gas pores, which can cause blisters during solution heat treatment and problems during welding. For parts that must be heat treated or welded, special alloys and process variants are used, or another process such as permanent mould casting is chosen.
Are die cast parts pressure tight?
They can be, if the design, the alloy and the process are set up for it. Housings that must be pressure tight are leak tested, and porosity can be sealed by impregnation where the specification allows it.
Send your drawing. You get a quotation in 3 to 5 working days.
Your drawings are handled confidentially; NDA on request.