Casting Design Allowances: die_casting
Casting process design allowances — linear and volumetric shrinkage percentages, external and internal draft angles, minimum wall thickness, surface finish Ra, ISO 8062-3 dimensional tolerance grades (CT1-CT16), typical and maximum part weight ranges, relative cost, and production rate for 7 casting processes (sand, investment/lost-wax, die casting HPDC, permanent mold, centrifugal, shell mold, squeeze casting) across 11 alloy families (gray iron, ductile iron, carbon steel, stainless steel, aluminum A356/A380, copper alloys, zinc, magnesium, titanium Ti-6Al-4V, nickel superalloy)
| casting process | alloy family | dimensional tolerance grade achievable | dimensional tolerance grade typical | draft angle deg external (deg) | draft angle deg internal (deg) | linear shrinkage pct (%) | max practical weight kg (kg) | min wall thickness mm (mm) | notes | production rate parts per hour typical (parts/hr) | relative cost | surface finish Ra um typical (um) | typical lot size min (pieces) | typical weight range kg max (kg) | typical weight range kg min (kg) | volumetric shrinkage pct (%) |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| die_casting | aluminum_A356 | CT2 | CT4 | 0.5 | 1 | 1 | 50 | 1 | LPDC or HPDC; better elongation than A380 after T6 heat treatment | 150 | medium_high | 1.6 | 500 | 30 | 0.05 | 3 |
| die_casting | aluminum_A380 | CT2 | CT4 | 0.5 | 1 | 1 | 50 | 0.8 | HPDC; A380 most common Al die-cast alloy; short die life for high-iron alloys | 200 | medium_high | 1.6 | 500 | 30 | 0.05 | 3 |
| die_casting | copper_alloys | CT3 | CT5 | 1 | 1.5 | 1.5 | 20 | 1.5 | Yellow brass/silicon brass C87850; high die wear; limited to smaller parts | 100 | high | 2.4 | 200 | 10 | 0.05 | 4.5 |
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