Editing Die casting (section)

==Cast metal==
The main die casting alloys are: [[Zinc Alloy Die Casting|zinc]], aluminium, magnesium, copper, lead, and tin; although uncommon, [[ferrous]] die casting is also possible.<ref name=D328>Degarmo, p. 328.</ref> Specific die casting alloys include: [[zinc aluminium]]; aluminium to, e.g. [[The Aluminum Association]] (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.<ref>{{Citation|title= Die Casting |publisher=efunda Inc|url= http://www.efunda.com/processes/metal_processing/die_casting.cfm |access-date=2008-04-12}}.</ref> The following is a summary of the advantages of each alloy:<ref name="NADCA">{{Citation|title=FAQ About Die Casting |url=http://www.diecasting.org/faq/ |access-date=12 April 2008 |url-status=dead |archive-url=https://web.archive.org/web/20101021064505/http://diecasting.org/faq/ |archive-date=21 October 2010 }}.</ref>

*[[Zinc]]: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
*[[Aluminium]]: lightweight; high dimensional stability for very complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at moderately high temperatures.
*[[Magnesium]]: the easiest metal to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.
*[[Copper]]: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.
*[[Silicon tombac]]: high-strength alloy made of copper, zinc and silicon. Often used as an alternative for investment cast steel parts.
*[[Lead]] and [[tin]]: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance. Such alloys are not used in [[foodservice]] applications for [[Lead poisoning|public health]] reasons. Type metal, an alloy of lead, tin and [[antimony]] (with sometimes traces of copper), is used for casting hand-set type in [[letterpress printing]] and hot foil blocking. Traditionally cast in hand jerk moulds, now predominantly die cast after the industrialisation of the type foundries.{{Clarify|reason=What is "hand jerk"? Also bad grammar.|date=September 2023}} Around 1900 the [[Hot metal typesetting|slug casting machines]] came onto the market and added further automation, with sometimes dozens of casting machines at one newspaper office.

{{As of|2008}}, maximum weight limits for aluminium, [[brass]], magnesium, and zinc castings are estimated at approximately {{convert|70|lb|kg}}, {{convert|10|lb|kg|abbr=on}}, {{convert|44|lb|kg|abbr=on}}, and {{convert|75|lb|kg|abbr=on}}, respectively.<ref>{{Citation|title= Alloy Properties|url= http://www.diecasting.org/faq/alloy_prop.htm|publisher= The North American Die Casting Association|access-date= 2008-04-12|url-status= dead|archive-url= https://web.archive.org/web/20130606062843/http://www.diecasting.org/faq/alloy_prop.htm|archive-date= 2013-06-06}}.</ref> By late-2019, press machines capable of die casting single pieces over-{{convert|100|kg}} were being used to produce aluminium chassis components for cars.<ref name="keller-2021-01-12">{{cite magazine|url=https://www.foundrymag.com/melt-pour/article/21152204/emerging-trend-larger-automotive-cast-parts-molten-metal-equipment-innovations|first=Jeff|last=Keller|date=2021-01-12|access-date=2021-01-18|department=Melt Pour|magazine=Foundry Magazine|title=Larger Automotive Castings Drive Innovation in Molten Metal Delivery|quote=new project at [[Tesla, Inc.|a large, California-based OEM of electric vehicles.]] … 105 kgs of molten aluminum … delivered in each shot.}}</ref>

The material used defines the minimum section thickness and minimum [[draft (engineering)|draft]] required for a casting as outlined in the table below. The thickest section should be less than {{convert|13|mm|in|1|abbr=on}}, but can be greater.<ref name=D331/>

{| class="wikitable"
|-
! Metal
! Minimum section
! Minimum draft
|-
| Aluminium alloys
| {{convert|0.89|mm|in|3|abbr=on}}
| 1:100 (0.6°)
|-
| Brass and [[bronze]]
| {{convert|1.27|mm|in|3|abbr=on}}
| 1:80 (0.7°)
|-
| Magnesium alloys
| {{convert|1.27|mm|in|3|abbr=on}}
| 1:100 (0.6°)
|-
| Zinc alloys
| {{convert|0.63|mm|in|3|abbr=on}}
| 1:200 (0.3°)
|}