Though in today’s market a number of casting services are available yet die casting and sand casting are most known by everyone. And each one accomplishes its desired goals. As the names are different, so are the functions and processes.
In the below process, we will explain the differences between die casting and sand casting along with their benefits and cost. And surely, this will help you out to determine which casting will suit your next project.
DIE CASTING VS SAND CASTING PROCESS
Here in this section, we will try to explain sand casting and die casting in detail to draw images.
WHAT IS DIE CASTING?
Die casting uses molten metal under extreme pressure to produce metal components. It is known that die casting includes a metal manufacturing process where molten metal is injected under high pressure (mostly at 30,000 psi (200 MPa) into the mold cavity.
And all the molten metal process is done by a machine known as a die casting machine. Usually, it is used to achieve the desired shape of metal and has its roots in industrial, automotive, households and lighting, and parts such as pistons, connecting rods, electronic enclosures, toys, plumbing fittings, and cylinder beds, etc.
WHAT IS SAND CASTING?
The process of sand casting includes a molten metal that is poured directly from a ladle to a sand mold. Unlike the die casting, there is no high pressure required in sand casting.
The sand mold is produced when a matchplate encloses it. Match Plate can be a pattern of plastic and wood. After the enclosure, sand is distributed around the matchplate and under the matchplate. Once you pack the sand in it, then the matchplate is removed and a cavity is put in with molten metal.
Finally, the metal becomes solidified, then mod is opened, and sand aborts the hot casing, and all steps complete the sand casting process.
Sand casting is considered important for the furniture industry because it proves cost effective for it. Because thick wall pieces can be created more precisely with sand casting.
DIE CASTING VS SAND CASTING
BENEFITS OF DIE CASTING VS SAND CASTING
Both are used widely in the market and both have their unique advantages. We will explain the advantages of each other so that you can collect the information for your next project.
DIE CASTING ADVANTAGES
- High speed production: Die casting is made of die casting mold thus can be achieved in specific tolerance and shapes. A little Machining is required and you can produce thousands of identical casting before launching additional tooling. Hence it is quite easy for mass production. Although the initial cost is high but becomes cost effective if you have a threshold of 1,000 quantities.
- Helps in simplified assembly
- Economical for mass production: The starting cost may be high but with this cost, you can produce a variety of items. The complex-shaped parts can be achieved with high performance and assembly work reduces. Other materials can be embedded in die casting methods including complex parts. It saves materials cost process.
- Variety of surface textures: Suitable for smooth textured parts as well as flawless parts. It offers you diverse flexibility to finish parts in a wide range of technology.
- Strength and weight: The parts created by die casting are stronger and more reliable than plastic injection molding which also has the same dimensions. As we explained earlier, thin-wall castings are lighter and stronger than other casting methods. Moreover, die casting does not have separate parts fastened together and or welded, therefore strength is due to alloy rather than joining process.
- Dimensional accuracy and stability: Thanks to dying casting, the parts produced by die casting are more stable and durable by maintaining close tolerance. The parts produced by die casting are also heat resistant. Excellent accuracy including die casting tolerance IT13~IT15 in GB/T 1800-2009, and higher precision goes at IT10~W 1 1., along with Surface finish which is 3.2~1.6μm. It saves a lot of Machining cost meanwhile.
SAND CASTING ADVANTAGES
- Low tooling cost with incredible result: Sand casting is best for low volumes ( under 1,000 a month), prototype castings and rapid Prototyping.
- More flexibility in term of size, shapes and weights:
- Alloy friendly – that can be used with almost any type of material, whereas in sand casting, parts can be produced with all types of alloy.
HOW DOES SAND CASTING IS DIFFER FROM DIE CASTING
As we mentioned earlier, both die and sand casting have their unique features to attract the clients. Beides advantages over each other both have differences as well.
Processes of both are different so as the application in different fields. Here are the differences…
A number of parts are manufactured via the die casting method including, pistons, connecting rods, electronic enclosures, toys, plumbing fittings, and cylinder beds, etc. Because all these fields require accurate and complex shape parts, that\’s why die casting is preferred to create these parts. Sand casting in this process cannot produce high quality parts.
On the other hand, sand casting is preferred for the furniture industry because it proves cost effective for it. Due to thick wall pieces can be created more precisely with sand casting. It\’s textural imprints enhance the decor of the furniture item with a granular finish . That\’s why it can be a disadvantage for small complex shaped products.
Alloy for die casting and sand casting are of different types. In die casting aluminum, Magnesium, zinc can be used, whereas in sand casting, parts can be produced with all types of alloy.
Surface finish is another difference between the two. Through die casting the surface of the part will be smooth but not in sand casting.
Sand casting is best for low volumes ( under 1,000 a month), prototype castings and rapid Prototyping. Although the initial cost is high but becomes cost effective if you have a threshold of 1,000 quantities.
LEAD TIME FOR METAL CASTINGS
Many folks are confused about the metal casting process and leading time, so they feel confused when to place an order
In project initial time, 30 to 45 days are taken to create the samples and metal patterns. If the sample is approved , the batch production starts.
Lead Time is measured when you place an order and when you get your casting, so a time between the order and casting.
However it is difficult to explain the exact time management, because sometimes production is so busy along with some quality issues. It can take longer time, and if production is not busy and the defective rate is relatively low then it shortens the period.
LEAD TIME FOR DIE CASTING
Set up time for die casting tooling takes 4 to 10 weeks and after that time it can produce almost 500, 000 castings within the production lifetime.
LEAD TIME FOR SAND CASTING
Lead Time for sand casting is almost 1-2 week and sometimes even less. Get your prototype done quickly without a heavy price as compared to die casting. Sand casting is very fast and rapid throughout the process.
COST OF DIE CASTING VS SAND CASTING
After reading the whole post, a question must arise in your mind, which casting method is more economical, die casting or sand casting. In our presence you don\’t need to be confused. In this section we will explain the cost difference between the sand casting and die casting.
Sand casting: It demands low investment in terms of tooling. A sand casting process typically requires $500 to $7,500 that usually depends upon parts complexity. It provides the best combination for metal.
Die casting: Die casting demands heavy investment as compared to sand casting typically $7.500 at the low end up to $75,000 at the high end up. But this high cost gives high quality parts and is worth your money.
As you learnt from our post about die casting as well as sand casting, their advantages, uses, applications in different fields, their differences, and all steps tell that both are the champions in their own fields.
The best choice is to discuss with our experts about your specific project and our expertise will fine-tune the details and provide the best casting process for the project.
If you find any other questions about sand casting and die casting processes and are confused about which will be suitable for your next project, contact Bohao prototype engineer online and get the best advice along with the best quote. Just upload your CAD model and contact us now!