Die Castings are used in high volume applications to produce high tolerance parts from materials including Zinc, Magnesium and Aluminium. More than 80% of all Die Castings are used within the transport sector.
The major trend in this market is the adoption and commercialisation of electric vehicles which will increase demand. Die Cast Aluminium is often used for electric motor components as they are lightweight and yet durable and able to maintain their mechanical properties at high temperatures. Die cast aluminium also offers excellent electrical conductivity. Although they are durable, die cast components are not suitable for structural parts and concerns have been raised over their part life in hot gas environments. As such it has become more common for die castings to be heat treated. Precipitation Hardening the hardness and mechanical strength of the cast parts are increased, but this also means additional machining time should be taken into consideration. Heat-treated Die Cast Aluminium has similar mechanical properties to Cast Iron.
Die Cast Aluminium is also growing in popularity in the aerospace sectors where it’s applications including both interior fittings and housing components. The lightweight and high precision nature of the die casting process make them ideal for this sector and indeed Magnesium alloys build on this and are being deployed in main drive systems and gearbox housings. Due to the high levels of temperature, wear and corrosion in aerospace application many die cast parts may also undergo some level of surface treatment; including metal finishes such as Iridite NCP, Anodising and Powder Coating depending on the application. Although the aerospace segment is still a niche market for the casting industry as a whole, the potential for innovation in this market which will drip down to other industries over time as research projects discover new applications.
The ability to produce intricate components is a key factor in the increasingly complex designs involved in medical devices. Applications for Die Cast Zinc in the Medical Industry include pacemakers, motor casings and protective caps for radiological equipment as well as ultrasound system components. There is a device range of applications within this field including electronic equipment, surgical equipment and diagnostic equipment.
Traditionally Die Cast Components are used in small to medium sized components but with higher volume applications in industrial and power generation industries it has become more common for larger sized parts to be manufactured this way.
Machining of Castings
Bronte Precision offer full machining of a wide range of cast materials and components including Die Castings, and arrange post-machining surface treatments with a local partner. We can also work alongside casting companies to produce original patterns and moulds. Bronte are ISO certified and based in Bradford, West Yorkshire.