• Die casting is a fairly specialised process which has developed more predominantly within

the 20th century. The basic process comprises of: molten metal is poured/injected into a
steel mould and via high velocity, constant and intensifying pressure (in pressure die
casting) and cooling the molten metal solidifies to form a solid casting. Typically, the
process itself only takes a few seconds and is a quick way of forming metal product from
raw material. Die casting is suited to materials such as tin, lead, zinc, aluminium,
magnesium to copper alloys and even iron alloys such as stainless steel. The main alloys
utilised today in pressure die casting are aluminium, zinc and magnesium. From the early
die cast machines which orientated die tools in vertical orientation to the now common
standard of horizontal orientation and operation, four tie bar tensioning and fully computer
controlled process stages the process has advanced throughout the years.
The industry has grown into a worldwide manufacturing machine, making components for
a variety of applications, many of which will be in reach from ones self as the product
application of die castings is so diverse.
Benefits of pressure die casting
Some of the benefits of high pressure die casting:
The process is suited to high volume production
Produce fairly complex castings quickly compared to other metal forming processes (eg.
machining)
High strength components produced in the as cast condition (subject to component design)
Dimensional repeatability
Thin wall sections possible (eg. 1-2.5mm)
Good linear tolerance (eg. 2mm/m)
Good surface finish (eg. 0.5-3 µm)

Hot Chamber Die Casting

The process of hot chamber pressure die casting involves the melting of metal ingot within
a furnace which is situated close/integral to the fixed half platen of the die casting machine
and injection of molten metal via a submerged plunger directly through the gooseneck and
nozzle and into the die tool. The gooseneck and nozzle require heating to prevent metal
freezing before it gets to the die cavity, the whole heating and molten metal element of this
process is where the designation hot chamber comes from. The casting shot weight is
dictated by the stroke, length and diameter of the plunger as well as the sleeve/chamber
size and the nozzle also plays a part which should be considered upon die design. Once
the metal has solidified in the die cavity (takes only a few seconds) the moving half platen
of the machine of which the moving half of the die is fixed to opens and the casting is
ejected off the die face and removed from the tool. The die faces are then lubricated via a
spray system, the die closes and the process cycles again.
Because of this “closed” metal melt/injection system and minimal mechanical movement
hot chamber die casting can provide better economies for production. Zinc metal alloy is
primarily used in hot chamber pressure die casting which has a fairly low melting point
which offers further benefits for low wear on machines (pot, gooseneck, sleeve, plunger,
nozzle) and also low wear on die tools (so longer tool life compared to aluminium die
casting tools – subject to casting quality acceptance).
 Hot Chamber
• Cold Chamber Die Casting
The name cold chamber comes from the process of molten metal being poured into a cold
chamber/shot sleeve which is attached through the fixed half die platen to the back of the
fixed half die tool. Molten metal holding/melting furnaces are typically located as close as is
practical to the shot end of the die casting machine so that a manual operator or an
automatic pouring ladle can extract the molten metal required for each shot/cycle with a
ladle and pour the molten metal into a pouring hole within the sleeve/shot chamber. A
plunger tip (which is a wearable and replaceable part, precision machined to the shot
sleeve inner diameter with allowance for thermal expansion) connected to the ram of the
machine pushes the molten metal through the shot chamber and into the die cavity. The
die casting machine when prompted will conduct first stage to push the molten metal past
the pouring hole in the sleeve. Further stages take place under increased hydraulic
pressures from the ram to inject the molten metal into the die cavity. The whole process
takes seconds, the quick and intensifying pressure as well as the drop in metal
temperature causes the metal to solidify in the die cavity. The moving half platen of the die
casting machine opens (of which the moving half of the die tool is fixed to) and ejects the
solidified casting off the die face of the tool. The casting is removed, the die faces are
lubricated with a spray system and then the cycle is repeated.
Cold chamber machines are suited for aluminium die casting, parts on the machine (shot
sleeve, plunger tip) can be replaced over time, sleeves can be metal treated to increase
their durability. Aluminium alloy is melted in a ceramic crucible due to aluminium’s relative
high melting point and the need to reduce the risk of iron pickup which is a risk within
ferrous crucibles. Because aluminium is a relatively light metal alloy it affords casting of
large and heavy die castings or where increased strength and lightness in die castings is
required.
 Cold Chamber
• Pressure Die Casting Tools
Overview of tool construction
A pressure die casting tool explained in simple terms: if you had a component that needed
to be cast you decide where on the component you would split it in half, two blocks of steel
would surround the component and meet flush around the component and where you have
determined where the split on the component is, you “remove” the component and the void
which remains is your die cavity. A die tool then requires an entry point and channel called
a runner/feed for the molten metal to enter the tool and into the die cavity. The remaining
basic requirement needed are small pockets or voids around the die cavity to allow the
molten metal to push any air into once it has filled the die cavity, these are called
overflows/vents which typically break off easily off the component after the metal has
solidified. Die design (and component design for die casting) is considerably more complex
than what is stated above and we will continue to go into more detail below.A die casting
tool can be as small or large or as simple and complicated as required and is primarily
dictated by the design of the component as well as economies for manufacturing, it is wise
to learn about designing for die casting and working with an experienced pressure die
caster such as Midland Pressure Diecasting when designing new components as a die
casters input will be vital to development of component design for feasibility of production
die casting. The following technical information we offer as a brief overview for designing
for die casting, there is much more to component and tool design than what is outlined
here and by working with Midland Pressure Diecasting we can offer more technical design
input into any project and you can be assured that your project will be in safe hands.
Die casting tool
A die casting tool comprises of two steel blocks which when assembled together form the
complete die cavity required to cast a component. The split on the component has a direct
bearing on the design of the die tool and can alter costs considerably as well as affect
future tool maintenance and upkeep.A die casting tool can be manufactured from a range
of tool steels and careful consideration should be made into the requirement of life
expectancy of the tool. A designer needs to consider tool life, how long will the tool be in
production? The volumes of die casting supply need to be considered as this will have an
impact on the wear on the tool. The process of die casting means a die casting tool needs
to be able to withstand quick temperature increases and sudden temperature decreases
many times an hour, sometimes many times a minute, throughout a production run. For
large scale operations this can be an ongoing non-stop cycle.
Split line on casting
 Because a die tool is effectively one tool split into two halves there must be a
corresponding split (split line) on the casting. The position and location of the split line on
the casting needs to be in the most effective place as to cause minimum disruption down
the line. Having a split line on a face will leave a witness line which will require secondary
process operations to remove if needed which adds to the cost of the component. If the
witness line is on an a-face (highly cosmetic and expected to be free of defects) then it is
advisable to design for the split line to be moved to another area on the casting, this
principle is doubly applicable if the surface is required to be porosity free.The location on
the split line will also have a bearing on the long-term condition of the die tool (and
corresponding press clip/trimming tool where applicable – a secondary tool required for the
removal of un-required excess metal such as the metal feed and overflows). Over time
areas on the tool will be prone to die erosion and wear so consideration should be input at
the design stage to have these in places where they will have minimal impact on the
component requirement and application.A tool designer will provide recommendations for
the best split lines but a component designer should also have some input in the best
places to consider for product application and also assembly with mating components.

Split line and witness line

• Draft angle
One of the most basic principles in designing for a die casting is the provision for
positive draft/draw taper. Avoid creating surfaces perpendicular to or with negative
draft taper to the die face line, negative draft will be impossible to cast without
additional sliding cores creating the feature, perpendicular surfaces do not allow the
ideal condition to allow the die to open without potentially causing damage to the
solidified casting and also damage to the casting upon ejection from the die face. Risk of
sticking of metal to the die impression or dragging on the component may also occur
due to not having enough draft taper on the component/die cavity impression. An
allowance of at least 0.5 degree of draft taper (the more the better) will make a huge
difference for casting consistency and production efficiency.
 Draft Angle
• Section thickness
As with any design methodology consideration should be put into component geometry,
why is the casting shaped as such, does the component need to be so “heavy.” The weight
element is important in die casting (as with any process which requires the provision and
processing of raw material). In first instance it determines how much material will be
required in producing the part which constitutes towards the price of the casting. Die cast
machines come in various sizes and configurations which determines whether they are
capable of producing a die casting. Wall section of a casting has an impact on the tool
design, how the molten metal will fill the cavity of the die, how the metal will solidify in the
die cavity, how long it will take to solidify etc.
Wall thicknesses of 2-3mm for aluminium and 1mm for zinc are typical examples and are
subject to the component design and application. Consideration for wall thickness should
allow for radiuses where sections intersect at a sharp angle for strength of the component
in that region, durability of that feature on the die tool and to aid in molten material flow
within the die cavity. Ideally wall section thickness should be the same throughout the
whole of the component (although in actual application this is sometimes difficult) as
changing from thin section to thick section can cause cavity filling and surface finishing
issues.
The cavity in the die must be filled with metal very quickly, the general timing is between
one hundredth and one tenth of a second and this is dependent on the casting size and
design. The wall thickness aided with radiuses will allow smoother metal flow to minimise
turbulence to prevent surface imperfections. A shorter die cavity fill time will aid in
providing a better surface finish on the casting.
Also when molten metal solidifies the volume of molten metal in the die cavity will shrink as
it cools, liquid metal must be available to fill the space created otherwise a shrinkage void
will remain which is why it is best to avoid sudden variations in wall thickness and avoid
thick wall sections completely where practicable.

Section Thickness
• Avoiding undercut features (avoid the need for moving cores)
Consideration of complex/undercut features within the component design at early stages
will save a lot of time later on. Complex forms, cored holes and undercuts can be a cast in
feature and calls for the implementation of sliding cores which in one way can be designed
to slide into position via angled guide pillars mounted onto one die half which locate the
slide core blocks on the opposite die half to move into position when the die closes and
opens. These slide cores can also be hydraulically operated with the use of cylinders. It is
 always preferred to avoid moving cores where possible as they add cost to the die tool,
they reduce casting cycle times and they also add into the probability factor for operation
and maintenance of the tool – they can be cause for variability on the casting dimensions
which require stringent quality control monitoring for critical areas and because they are a
moving part they are prone to wear and require maintaining.

Avoiding Undercut Features

• Taking advantage of cored holes
Secondary processing can be greatly reduced by using cores in the die tool to cast holes
at the casting stage. Small holes can be cast in, they can also be cast without taper
though consideration for tool life and maintenance as well as production need to be
considered for viability to implement such casting designs.
Strengthening ribs
An excellent alternative to having areas of thick material on a casting is to include
strengthening ribs which will provide added strength to a component whilst in some
applications also allowing the removal of material within the same region for the
benefit of component weight reduction. The ribs should be designed in a way to allow
molten metal flow to aid in die cavity filling, they should also be rounded and blended
 (with rads) to further enhance metal flow and reduce chances of the casting sticking to
the die face upon metal solidification and ejection.

Avoiding Undercut Features

• Design edges and features to

prevent local die overheating
Small features/sections on a die impression such as a sharp edge or a protrusion such as a
core for a hole may be prone to overheating which can lead to issues to cause drag marks and
porosity depending on the component and how the die is designed. Such features should have
thought put into alternative design as in the long run chances of tool breakage and
maintenance can be vastly reduced to benefit in longer tool life.

Prevent Overheating
• Required casting surface finish
Although smooth surface finishes on a casting are achievable as cast, certain applications may need
additional machining in order to provide the desired surface finish. Further surface preparation is
advisable for castings which require powder coating, an alternative feature is to add texture to the
die surface but this is component dependent. For secondary processes such as linishing and
polishing, where applicable simple, flat-section surfaces are preferred and areas with blind holes
and recesses should be avoided as they tend to trap abrasive/polishing compounds which causes
problems when plating parts. Large flat sections should be slightly curved (convex/concave) as
they provide a smooth uniform surface to ease processing when linishing and polishing. Sharp
junctions should be avoided in a casting required for electro plating as are blind holes, v-like
grooves and upstands, such features should be designed with radiuses to allow even plating
thickness to deposit, reduce plating times and increase durability of the plating, this also applies
for castings which require powder coating. If lettering is to be cast in on a component these are
better off to be a raised feature on the casting rather than sunk in, this will also benefit the
durability of this feature on the die tool.
Casting threads
Threads in castings can be cast in, this is more suited to zinc die casting as the material allows for
fine cast in detail. Consideration has to be put into production efficiency due to the configuration of
the die tool required to cast threaded parts reduces the cycle time and makes the tooling more
expensive.
Casting with inserts
Where required, for strength applications for example, inserts can be cast into a die casting. The
die tool needs to be designed in a way which allows the insertion and retention of the inserts upon
each die opening cycle and clearance for molten material to cast around the inserts sufficient
enough to provide enough strength for their product application without breaking out the casting,
consideration also needs to be made for correct seating so the insert is always cast in the correct
position on every cycle. Casting with inserts slows down the cycle time which increases component
cost so a designer should consider whether this is necessary at the cast stage or whether an insert
can be assembled in a secondary process.
Casting Alloys
Midland Pressure Diecasting manufacture die castings for a range of applications in a variety of
aluminium and zinc metal alloys. Our technical team can offer recommendations on casting
materials which will meet your specifications for die cast product. If there is a specific casting alloy
you need please feel free to contact us as we will be able to help with your supply requirements.
The following technical descriptions define typically alloys utilised and the information is offered
as a guideline only.
Aluminium Alloys
Aluminium alloy die casting contributes the largest percentage of material in die castings today. As
the material and process has become better understood throughout the 20th century more and
more uses of the material within die castings have developed. Aluminium offers strength
properties above those for steel and iron as well as reduced weight which is why automotive is one
of the largest industrial sectors with use of aluminium die castings.
Aluminium alloys are well suited to machining and can offer faster and easier machining solutions
compared to other materials subject to utilising the ideal machining characteristics. Aluminium
alloys compared to steel and cast iron do not suffer from ductile-brittle transformation so can be
used in cryogenic applications without any sudden loss in ductility of impact strength. Aluminium
is often chosen for it excellent resistance to corrosion, this is in part due to aluminium having a
natural oxide film which develops when in contact with air which reforms if damaged, alloys with
high content of silicon such as LM6 aid in corrosion protection and use of castings in outdoor
environments and the material can also be powder coated, electro-plated or anodised for further
corrosion protection.
Aluminium is an easily recyclable material hence its use in many applications.
LM-6
BS Ingot Colour Code: Yellow
LM 6 (BS 1490:1988) – (similar to EN AC/AB 44100/44000, (USA 369.1/A413/B413), (France
AS12/13), (Italy UNI4514), Germany (AlSi12, 230), (Japan AC3A))
LM6 (Al-Si12 type) is one of the most widely used aluminium alloys in die cast production. Due to
the high silicon content it has excellent fluidity for casting purposes and affords high resistance to
corrosion. The alloy provides excellent pressure tightness and hot tearing properties. The material
can be machined and care must be taken in utilising the correct tools to minimise wear due to the
high silicon content. LM6 is suited to post casting finishing such as powder coating, electro plating
and anodising which further enhances its corrosion resistance properties in real world
applications.
Alloy composition
SymbolMin % Max %
Magnesium Mg – 0.10
Silicon Si 10.0 13.0
Titanium Ti – 0.2
Manganese Mn – 0.5
Iron Fe – 0.6
Nickel Ni – 0.1
Copper Cu – 0.1
Zinc Zn – 0.1
Tin Sn – 0.05
Lead Pb – 0.1
Others (Total) – 0.15
Aluminium Al Remainder
Typical physical and mechanical properties (as cast)
Casting Temperature -725 °C
Freezing Range 565-575 °C
Thermal Conductivity at 25 °C 0.34 cal/cm2/cm/°C
Coefficient of Expansion per °C at 20-100 °C20 x 10-6
Electrical Conductivity 37% IACS
Density 2.65 g/cm3
0.2% Proof Stress 120 N/mm2
UTS 280 N/mm2
Elongation 2-5%
Hardness 55-60 BHN
LM-24
BS Ingot Colour Code: Red/Blue
LM 24 (BS 1490:1988)– (similar to EN AC/AB 46500, (USA 380/A380/B380), (France AS9U3Z),
(Italy G-AlSi8.5Cu), Germany (G-AlSi8Cu3, 226), (Japan AC4B, AD10))
LM24 (Al-Si8Cu3Zn type) is the most widely used aluminium alloy in die cast production together
with LM2 they are equally suitable for most applications of die castings. This alloy is highly suited
to machining and has better mechanical properties than LM6, its corrosion resistance is good in
normal atmospheric conditions and can be further improved via post cast finishing such as powder
coating and anodising. It offers excellent pressure tightness and hot tearing properties.
Alloy composition
SymbolMin % Max %
Magnesium Mg – 0.30
Silicon Si 7.5 9.5
Titanium Ti – 0.2
Manganese Mn – 0.5
Iron Fe – 1.3
Nickel Ni – 0.5
Copper Cu 3.0 4.0
Zinc Zn – 3.0
Tin Sn – 0.2
Lead Pb – 0.3
Others (Total) – 0.50
Aluminium Al Remainder
Typical physical and mechanical properties (as cast)
 Casting Temperature -700 °C
Freezing Range 520-580 °C
Thermal Conductivity at 25 °C 0.23 cal/cm2/cm/°C
Coefficient of Expansion per °C at 20-100 °C20 x 10-6
Electrical Conductivity 24% IACS
Density 2.79 g/cm3
0.2% Proof Stress 150 N/mm2
UTS 320 N/mm2
Elongation 1-3%
Hardness 85 BHN
Zinc Alloys
Zinc alloy (also commonly referred to/identified/prefixed as ZL, ZA, Mazak, Zamak) is one of the
most widely used materials for die castings in the world. The properties of zinc alloy make the
material well suited for die castings required for decorative purposes and functional applications,
the economics of zinc die casting are also very favourable. The hardness and dimensional stability
of zinc make the material suitable for parts which are required in mechanical assemblies, its
thermal and electrical conductivity make it a good choice for electrical component application as
well as providing electromagnetic shielding. Zinc alloys (especially the ZA12 alloy) are non-
sparking and are suited for applications within hazardous environments such as mines and fossil
fuel refineries. Zinc castings are highly versatile for post cast surface finishing and can be made to
look like other materials/cosmetically aged via painting and plating as well as other
industrial/chemical processes.
Due to the fairly low melting point for zinc compared to other metal alloys there are significant
energy savings as well as the reduced impact on the environment. The lower temperatures also
mean there is less of a thermal impact on tool steel, therefore providing die life advantages over
other casting materials. Zinc is one of the cleanest materials to use for molten processing purposes
and is easily recyclable.
ZL-3
BS EN Ingot Colour Code: White/Yellow
ZL 3 (BS EN 1774:1997) – (similar to ZA3, Mazak 3, Zamak 3)
ZL3 is widely used as a general purpose zinc alloy for the hot chamber pressure die casting
process. The alloys properties ensure its wide application of uses within the automotive and
engineering industries. ZL3 is widely used within the hardware and lock industries as well as for
industrial fixings, furniture fittings, toys etc. The chemical composition of ZL3 conforms to the BS
EN 1774:1997 standard which is widely standardised across Europe.
ZL3 is suited for machining, polishing, lacquering, powder coating and electro plating – if a high
cosmetic plating finish is required zinc is recommended.
Alloy composition
SymbolMin % Max %
MagnesiumMg 0.035 0.06
Aluminium Al 3.8 4.2
Silicon Si – 0.02
Iron Fe – 0.020
Nickel Ni – 0.001
Copper Cu – 0.03
Cadmium Cd – 0.003
Tin Sn – 0.001
Lead Pb – 0.003
Zinc Zn Remainder
Typical physical and mechanical properties (as cast)
Casting Temperature 405-425 °C
Freezing Range 382-387 °C
Specific Heat 0.4187 J/gk (0.10)
 Solidification Shrinkage 1.17 cm/m (0.14 in/ft)
Casting Shrinkage 0.006 mm/mm (0.006 in/in)
Thermal Conductivity at 18 °C 113 W/m°C (0.27 CGS)
Linear Thermal Expansion per °C 28 x 10-6
Electrical Conductivity at 20 °C 26% IACS
Specific Gravity 6.7
Density 6,700 Kg/m3 (0.24 lb/in3)
Tensile Strength at 20 °C 241-283 N/mm2 (41,000 lbf/in2)
Elongation at 20 °C 10-16% %in 2in
Impact Strength at 20 °C (un-notched)56.9 J (42 ft.obf)
Hardness 82-87 BHN
ZL-5
BS EN Ingot Colour Code: White/Black
ZL 5 (BS EN 1774:1997) – (similar to ZA5, Mazak 5, Zamak 5)
ZL5 is used within the hot chamber die casting process whereby a stronger alloy than ZL3 is
required. It is used where critical dimensional accuracy isn’t too important (don’t forget zinc is
easily machined if needed) but strength and hardness is more of a factor in the end product. ZL5 is
also suitable where small details in castings is a requirement or where surface preparation for
plating using other zinc alloys is an issue. ZL5 is more expensive than ZL3 due to the higher copper
content. The chemical composition of ZL5 conforms to the BS EN 1774:1997 standard which is
widely standardised across Europe.
ZL5 is suited for machining, polishing, lacquering, powder coating and electro plating – if a high
cosmetic plating finish is required zinc is recommended.
Alloy composition
SymbolMin % Max %
MagnesiumMg 0.035 0.06
Aluminium Al 3.8 4.2
Silicon Si – 0.02
Iron Fe – 0.020
Nickel Ni – 0.001
Copper Cu 0.7 1.1
Cadmium Cd – 0.003
Tin Sn – 0.001
Lead Pb – 0.003
Zinc Zn Remainder
Typical physical and mechanical properties (as cast)
Casting Temperature 405-425 °C
Freezing Range 379-388 °C
Specific Heat 0.4187 J/gk (0.10)
Solidification Shrinkage 1.17 cm/m (0.14 in/ft)
Casting Shrinkage 0.006 mm/mm (0.006 in/in)
Thermal Conductivity at 18 °C 108.9 W/m°C (0.26 CGS)
Linear Thermal Expansion per °C 28 x 10-6
Electrical Conductivity at 20 °C 26% IACS
Specific Gravity 6.7
Density 6,700 Kg/m3 (0.24 lb/in3)
Tensile Strength at 20 °C 270-328 N/mm2 (47,000 lbf/in2)
Elongation at 20 °C 7-13% %in 2in
Impact Strength at 20 °C (un-notched)54-65 J (43 ft.obf)
Hardness 80-92 BHN