Die casting ensures a more reliable and recyclable manufacturing process as an environmentally friendly manufacturing method
. Die casting provides highly similar complex shapes or pieces that can be manufactured at a fast rate. This is done using a mould, and as such, it enforces the three Rs of environmental safety. It reduces the need for extensive changes, additions or evaluations of the piece; as there is one cast, it can be reused multiple times before needing to be changed. Finally, most materials used in this area are recyclable.
An example of this is magnesium. Moreover, due to its recyclable capability, it can be used to manufacture multiple pieces in a day. Additionally, it provides durable and stable parts, which is a must, especially during rough use. All of this together ensures that there will be high savings in both labour and cost.
When it comes to the metals used for die casting, magnesium stands apart. Due to its lack of susceptibility to extensive hydrogen porosity, it acts as a good source for ensuring vital die pieces that are sturdy and stay for an extended period. Moreover, due to its greater durability level and light weighing properties, magnesium - mainly AZ91D - is the best choice to cast with. AZ91D Magnesium has been noted to have corrosion resistance properties and this, when combined with the other features as mentioned earlier, brings die casting to a whole new era. Though magnesium has been used for a while in die casting, it should not be discontinued mainly due to its durability and environment-friendly nature.
With lower density and a relatively lower cost, Magnesium has the perfect blend of characteristics that ensures the best use at the best rate. Its ability to be used in hot and cold die casting machines brings an added advantage. Due to its flexibility, magnesium offers multiple alloys for different needs. A few of these include AZ91D magnesium alloy, which assists in creating durable material and AM60B magnesium alloy, which allows for a more malleable material with a lower strength level (this allows for more flexibility compared to the AZ91D magnesium alloy).
With such features, magnesium takes the top position when a person looks for a metal that can be used to manufacture different components. Moreover, magnesium has multiple benefits compared to aluminium, steel, or even plastic. Apart from the fact that it is the lightest of the metals, it is a lot more wear-resistant when compared to plastic. Apart from this, magnesium has high thermal conductivity compared to plastic or steel. Moreover, compared to aluminium, the lifespan of the moulds once used with magnesium is comparatively high.
Furthermore, it has high impact resistance and is the lightest of all structural materials, bringing together the best of both worlds in a short metal. Due to such features, magnesium alloys would be perfect for mechanical or automated parts. But the metals' ability to work under different conditions ensures a more dynamic use of the material when manufacturing. Overall, with the ability to ensure that you have the best material at a reasonable price coupled with being non-toxic to the environment, magnesium provides a win-win situation on almost all fronts. It would be beneficial and a great idea to move forward with considering and using magnesium as a metal for die casting.
Research Paper Used - https://www.sciencedirect.com/science/article/pii/S2213956713000030