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The following article was published in our article directory on August 11, 2015.
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The Process for Castings and Its Cost Levels

Article Category: Business

Author Name: Castings Aluminum

Die casting is a widely used system in the production of multiple parts for many mechanisms such as automobiles, light fixtures, pump housing and audio speakers. Most manufacturers opt to use the process because aside from being efficient, it also guarantees low production prices and time.

This article that you are reading gives an overview on the die casting process and prices, so that interested consumers and producers will have an idea regarding the metal materials they might need for their own purposes. For the sake of a simpler overview, the die casting procedure and prices will be discussed in terms of car parts production.

This die casting system and prices can be classified into four main steps for easier cost and material quoting. These four processes include lamination and stacking, die casting and rotor core manufacturing model, induction rotor assembly and bar-wound stator assembly model.

Slitting and blanking both the stator and rotor laminations is the first sub-step in the initial stage of the die casting system. This period is called the lamination and stacking step. After the first sub-step, the blanked stator and rotor laminations are lightly stacked and bound with a wire. Then annealing comes next where any stresses found in the material is eliminated.

If necessary, the two laminations will then be joined using male-female locking units. For some mechanisms or materials, the joining period is skipped. As for the cost, the price of this first period in the die casting system is computed as the price of the average number of laminations needed.

The following phase is the die casting and manufacturing of the rotor core. Simply put, this phase involves melting, heating and stacking, die casting, deburring (after inertia spin or friction stir welding), keyway broaching, heat treating and protective coating (only if the metal used is magnesium).

Seeing an overview of the entire die casting procedure and prices is also possible by understanding the next phase: the induction rotor assembly. This step has more sub-steps than the previous one and therefore costs more money and time. The sub-steps include the examination, balancing, assembly and testing of the rotor wheel. The cost for this phase is generally user-defined, and proper adjustments must be made depending on the measurements of particular parts.

Finally, there comes the bar-wound stator assembly and understanding this step can give you an idea about die casting system and prices. In this last phase, the stators are assembled (the sub-steps of which are very similar to the assembly of the induction rotor) and then the rotors are added to the stators. Housing components are usually necessary to keep the components of the motor together, but it is sometimes not used to reduce the weight of the final output and the cost of production.

Following the last step, the material then proceeds to the final assembly, which involves putting all the components together to form the finished product.

Now for the prices (in terms of US dollars), the cost of die-casted materials can range from as little as ten cents per piece to thousands of dollars. This depends on the size of the part and its planned use.

Keywords: die castings manufacturing parts tooling aluminum zinc production

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