How Alternative Industries Are Utilizing Die Casting

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Elizabeth Johns
5 years ago
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1 How Alternative Industries Are Utilizing Die Casting

2 Die Casting Provides Versatile Solutions for Diverse Applications A traditional method of high-volume parts production, die casting is used in a wide range of alternative industries. Flexible, reliable, and highly repeatable, die casting provides a versatile solution for many applications and allows for various surface finishing options. Applications Found in many products and industrial systems, die cast parts and components provide dependable solutions for diverse applications. Die cast parts are particularly well suited to the following industries: Industrial Despite its long history as an industrial production method, die casting is only now beginning to be adopted by some traditional industries. In the marine, pump, and compressor industries, specifically, manufacturers are increasingly seeking porosity-controlled die castings for valve bodies. The marine industry requires die castings in power steering systems, and they are used in a variety of pump and air compressor applications. Medical and Dental The medical and dental equipment industries, meanwhile, utilize precision die casting for a wide variety of components, which are used in diverse applications, including: Dental operatories EKG machines Electronically operated hospital beds Medical monitors Portable oxygen pumps Ultrasound equipment X-ray machines Die cast parts aren t just used in traditional industries; alternative industries are increasingly utilizing this process, as it provides an effective way to reduce costs and keep down weight without sacrificing strength or durability. All of these applications require high strength and low weight, electromagnetic and radio frequency shielding, low cost, and incredible part complexity all of which can be easily achieved with die casting. Phone: (847) Fax: (847) help@diecastingdesign.org 2

Transportation In the past, the automotive industries have opted for strength over weight, particularly for structurally important vehicle components that help ensure passenger and driver safety.

3 Transportation In the past, the automotive industries have opted for strength over weight, particularly for structurally important vehicle components that help ensure passenger and driver safety. More often than not, stamped steel is used for these purposes. Two factors, however, are starting to change that. First is growing consumer pressure more and more, consumers want greener cars with better fuel economy, and producing lighter vehicles is a great way to achieve this. Second, there have been several improvements in the die casting process, and, more importantly, in die casting alloys that have allowed the production of castings that feature the high strength of steel at a much lighter weight. Electronics and Telecommunications Advancements in precision die casting have also increased the overall usefulness of the process, both for complex part production within the medical industry, for instance and small parts alike. Therefore, die casting is now more frequently being used in electronics and telecommunications applications such as: Commercial scales Connectors Control panels Flow meters PC board assemblies Radar detectors Servo drives The light weight of die castings and the increased conductivity of new casting alloys are also making this process more popular for the abovementioned applications. Phone: (847) Fax: (847) help@diecastingdesign.org 3

4 Recreation The recreation industry is increasingly making use of the versatile die casting process. While there is some overlap in this sector for example, the rising popularity of die cast parts for RVs and other recreational vehicles, such as ATVs, has followed the same trends as the automobile industry other areas within the industry represent steadily emerging alternative industries. The sport-shooting sector, for instance, can benefit greatly from die cast parts to ensure strength while remaining lightweight. Risers the primary section of an archery bow and various riser accessories, such as spotting-scope attachments, are particularly well suited to die casting. Alternative and Renewable Energy Perhaps more than any other emerging industry, the renewable energy sector has made use of die casting for a wide range of applications. Magnesium alloy die castings are the de facto standard for a number of wind turbine subassemblies thanks to die castings superior strength and remarkably reasonable weight, which can be as much as 60% less than comparable steel parts. This makes die castings essential in applications in which higher weights result in decreased efficiency. Die castings have also played an integral role in the solar power industry. Lightweight, durable, and strong, magnesium alloy castings are perfect for use in the extreme, challenging environments in which solar arrays are often installed. Magnesium is also inherently highly conductive and effectively shields against electromagnetic interference. In many ways, the renewable energy industry would not be what it is today without die casting. It s worth noting the intersections of the above-mentioned industries. The automotive and alternative/renewable energy industries, in particular, commonly considered to be at odds with each other, actually intersect in various ways. For example, thanks to state-of-the-art super-vacuum die casting processes and certain newly designed magnesium alloys, the manufacture of the inner panels of vehicle doors could effectively be revolutionized. The die casting process could produce door panels in a single step, using half the amount of energy needed for the current multi-step stamping and joining process. And the use of these door panels, which are just as strong as traditional steel door panels, could reduce door weight by 60%, resulting in considerable fuel and carbon emission reductions. Phone: (847) Fax: (847) help@diecastingdesign.org 4

About NADCA In 1989, the American Die Casting Institute and the Society of Die Casting Engineers merged to create the North American Die Casting Association (NADCA), representing a combined 93 years

5 About NADCA In 1989, the American Die Casting Institute and the Society of Die Casting Engineers merged to create the North American Die Casting Association (NADCA), representing a combined 93 years of die casting experience. Today, 28 years later, NADCA is the largest die casting association in the Americas, serving die casters in the United States, Mexico, and Canada. NADCA focuses on die casting design improvements, hosts relevant training sessions and expositions, and markets and advocates on behalf of die casters and related industry professionals. Most importantly, we both fund and lead expansive research and development efforts and have built a considerable library of educational and reference materials. To learn more about NADCA and the role of die casting in the above-mentioned applications and other emerging industries, contact our team today. Contact NADCA View Our Resource Library North American Die Casting Association 3250 N. Arlington Heights Rd Ste 101 Arlington Heights, IL Phone: (847) Fax: (847) help@diecastingdesign.org Phone: (847) Fax: (847) help@diecastingdesign.org 5

1 ZSI Product Experience Examples

www.zsind.com 1 ZSI Product Experience Examples www.zsind.com 2 Casting and machining (1) 1 Material: Grey Iron GG25 Process: Sand Casting Vacuum Pump 2 Material: Cast Iron GG25, GGG40 Process: Sand Casting