Differences and Advantages of Powder Metallurgy vs. Die Casting

August 28, 2020

Manufacturers and other related industries consider numerous factors in choosing the best metal forming process for their metal products or components. They must consider the quality of the product and its associated implications. They also have to ponder on the mechanical properties and the intended applications of the same product. The overall cost or pricing of the product can likewise affect their decision when it comes to choosing the best process for their operations.

Two processes that manufacturers can choose are powder metallurgy and die casting. These processes may share some similarities when it comes to a few things. However, they may also have distinct qualities that make one process more advantageous in specific applications and instances than the other.

Qualities of Powder Metallurgy

Powder metallurgy is a type of metal forming process that is initially conducted by compressing metal powders into a shaped mould. Once the compact is formed, the manufacturer will then subject it to heat that is below their respective melting points through a sintering oven. At this point, all the metal powder will be compressed tightly until the finished metal product is formed. All the steps involved in powder metallurgy avoid the need to conduct any metal removal process, resulting in a decrease in yield losses in manufacturing and overall cost.

What is great about powder metallurgy is that it can easily produce products that are at or close to the intended shape, form, and dimensions. Complex or unique shapes can also be achieved whenever this metal forming process is used. The production of metal parts and components in moderate to high volume is likewise possible with powder metallurgy. And for its product, the manufacturer may expect it to obtain a good surface finish, controlled porosity, enhanced strength and reliability, increased wear resistance, and long service life. Products out of powder metallurgy are also cost-effective.

Qualities of Die Casting

Alternatively, die casting is a metal forming process that subjects molten metal under high pressure and high filling speed into a mould cavity. Alloys that are used for die casting typically have low melting points are made from non-ferrous metals. The molten metal from this process typically comes from a furnace where non-ferrous metals are melted. Consequently, this specific metal is injected into the dies, which can be found in the die casting machine. The die casting machine then cools and solidifies the molten metal component.

Die casting is utilised by manufacturers and other industries due to its ability to quickly produce materials. Mass production of complex shapes with little to no machining requirements is possible with die casting. Products that are processed by die casting can contain enhanced durability, improved stability, and smooth or textured surfaces. These products can even be plated or finished without any complicated surface preparation. Die casting products can also make the assembly simpler as they can easily provide fastening elements like bosses and studs.

Powder Metallurgy vs. Die Casting

The whole process of powder metallurgy tends to bring more advantages compared to the die casting. It can provide more consistent and high-quality products. The products they can produce can also have greater flexibility and higher variability. The cost of conducting powder metallurgy is also cheaper.

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