What are the different types of die casting

Die casting is a metal casting process used to produce accurate and often intricate components. Molten metal is poured or injected into metal dies and allowed to solidify. The parts are then removed from the mould and put to use after minimal finishing operations.

The process is primarily used for casting non-ferrous metals such as aluminium, magnesium, zinc and their alloys, but can also be used for other metals with comparable melting points.

There are several distinct die casting methods, each with its own advantages depending on the application.

Types of die casting

Cold-chamber die casting

Cold-chamber die casting is used for metals with a higher melting point, such as aluminium. The metal is melted in a separate furnace before being added to an injection chamber, where a plunger moves it into the cold mould. This allows the metal’s heat to stabilise the processing temperature throughout the cycle.

Hot-chamber die casting

Hot-chamber die casting is used for high-volume production. The furnace is part of the machine itself, meaning the metal retains its temperature when injected into the mould. This method offers faster processing times, though it does come with higher system costs and maintenance requirements.

High pressure die casting

High-pressure die casting is particularly suited to producing complex parts with thin walls down to 0.6 mm. Molten metal – typically aluminium or zinc – is injected under high pressure into a steel mould until it solidifies. It is widely used in sectors where precision, high surface quality and production consistency are essential.

Vacuum die casting

In vacuum die casting, a vacuum extracts air and gases from the die cavity before the molten metal is injected. Ideal for complex, thin-walled or heat-treatable parts, this process virtually eliminates air porosity, resulting in denser, stronger parts with better surface finishes.

Squeeze die casting

In squeeze die casting, molten metal is poured into an open die before a hydraulic upper die slowly closes to squeeze the metal as it solidifies. This eliminates gas and shrinkage porosity, producing highly dense parts with superior mechanical properties – making it well suited to high-performance structural components.

Gravity die casting

Gravity die casting involves pouring molten metal into a permanent mould using gravity alone. Particularly effective for medium to high volume production of aluminium parts, the slow pouring and controlled solidification creates denser castings with reduced porosity.

Low pressure die casting

Low-pressure die casting is a process where molten aluminium or its alloys are forced upward from a sealed holding furnace into a reusable metal die using low gas pressure. The steady, bottom-up fill reduces turbulence, producing high-strength, low-porosity castings.

Benefits of die casting

Die casting can produce complex designs with tight tolerances and smooth surface finishes. It offers an efficient, effective and cost-effective alternative to other casting methods, helping to save time and reduce costs. With quick cycle times and high material efficiency, particularly when using low melting point metals, it is well suited to high-volume manufacturing.

Die casting from Roston Castings

With over 60 years of experience, we have supplied high-quality aluminium castings for a wide range of technical applications and are trusted by leading manufacturers across automotive, aerospace, agriculture and engineering.

We understand the importance of reducing cost per part without compromising on quality. That is why we work closely with our clients to provide a complete end-to-end solution that saves time, reduces costs and ensures reliable results from a trusted supplier.