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Frequently Asked Questions - North American Die Casting Association

Sep. 08, 2025

Frequently Asked Questions - North American Die Casting Association

The earliest example of a die casting by pressure injection (as opposed to gravity pressure) occurred in the mid-s. A patent was awarded to Sturges in for the first manually operated machine for casting printing type. This process was limited to printer’s type for the next 20 years, but development of other shapes began to increase toward the end of the century. By , commercial applications included parts for phonographs and cash registers, and mass production of many types of parts began in the early s.

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The first die casting alloys were various compositions of tin and lead, but their use declined with the introduction of zinc and aluminum alloys in . Magnesium and copper alloys quickly followed, and by the s, many of the modern alloys still in use today became available.

The die casting process has evolved from the original low-pressure injection method to techniques including high-pressure casting (at forces exceeding pounds per square inch or 31 megapascals), squeeze casting, and semi-solid die casting. These modern processes are capable of producing high integrity, near net-shape castings with excellent surface finishes.

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As with any manufacturing process there is an impact on the environment. Melting metal and running machines require significant amounts of energy and wastewater needs to be properly treated. Die casting limits the overall impact on the environment by using a significant amount of recycled materials (which is less energy intensive to produce) and producing thin walled, light weight components (which reduce the fuel consumption on cars and trucks).

Die castings are recyclable components with engineering advantages not available in other metalforming processes. The major cost and performance benefits of parts consolidation possible with plastic components can be carried forward in die casting designs with additional advantages.

Over 95% of the aluminum die castings produced in North America are made of post-consumer recycled aluminum. Since the production of recycled aluminum alloy requires approximately 5% as much energy as primary aluminum production, there is a dramatic conservation of nonrenewable energy resources.

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