Surface finish of die cast auto parts

 Die cast are traditionally focused in the automotive industry. The UAE automotive market grew by 19.7% in 2010 to US$11.1 billion (Dh40.7 billion)up from US$9.2 billion (Dh33.7 billion)in 2009, according to a study by the Ministry of Foreign Trade.
Die-casting is similar to permanent mould casting except that the metal is injected into the mould under high pressure of 10-210Mpa (1,450-30,500)psi. This results in a more uniform part, generally good surface finish and good dimensional accuracy, as good as 0.2% of casting dimension.
For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size. The surface finish on a die cast component is unsurpassed by any other die cast metal. In addition, electroplated and painted finishes can equal or exceed the aesthetic qualities of similar finishes on moulded thermoplastics, while providing an engineering structure only possible with metal.

Selecting a finish
The first step in selecting a finish for die cast parts is to determine how much corrosion resistance the part will require. Constantly wetted parts, and parts to be used outdoors in industrial applications, corrosion resistance should be the first consideration.
All decorative finishes require a good quality surface and internal die cast structure to yield the desired effect. The reason for this is that during plating and painting processes, the die casting is heated, which may expose and highlight blemishes on the surface. These effects may be minimised by good component and tooling design.
During the assessment of visual impact during component design, requirements are sometimes over-specified, leading to higher costs. These can be avoided through a greater understanding of the finishes and textures available from Dynacast and their likely impact on the final product. Texturing applied to the tooling cavity can dramatically improve the repeatability and yield of plated components.
All castings exhibit small levels of internal porosity, so for components requiring decorative finishes, designs and processes that produce denser castings are necessary. The smoother and shinier the surface requirements, the denser the die casting will need to be. For the most mirror-like finishes, such as chrome plating, buffing operations may be required between plating stages (first copper, then nickel and finally chrome in this case). Satin finishes can be achieved by brushing the die casting. Other effects may be achieved by designing them into the tooling or additional operations.
Special considerations must be included in part design for electroplating and painting of components. Sharp corners, edges and posts increase electrical current, producing thicker coverage, while blind holes, deep channels and internal features receive less current and therefore less coverage. Another design consideration related to blind holes and deep channels, is that they restrict drainage, which could lead to excess coverage and restrictions in features. The temperature of the process must be known during the design process so that component and tooling design are matched to it, minimising potential porosity and surface finish problems.
Cars have the most number of die cast parts, as it mostly consists of little metal parts. There are so many examples of die casting automotive parts available in the market today.
Examples of die casting automotive parts:
1)Engine Parts: Engine cylinder heads and gas engine parts are mostly composed of die cast aluminum parts.
2)Stator: Stators are also made by die casting. Due to its variation in size, die casting is the best method of manufacturing this kind of mechanical part. 3)Brackets: Another example of die castedLebron XIII Low EP