Die castings can be mass produced at high volumes. Both intricate shape and thin sections can be cast in die castings. Die castings are typically limited to thin wall applications. Die castings have a higher propensity for entrapped air since the metal is flowing into the cavity with high velocity and turbulence. Because of the potential for entrapped air, die castings are normally not heat treated.
Heat treating a die casting can cause a blistering on the surface of the casting.
Hydrogen shrinkage is also a concern in the production of die castings. Initial investment for die castings are very high, primarily the cost for the tooling die used in the casting process. The two primary variations of the die-casting process are the hot and cold chamber processes. This unique process is, in reality, a variation on the low pressure process, but one that has several distinct refinements specific to high integrity aluminum parts. A unique method is employed to keep a constant melt level in the furnace, avoiding back-surges such as are sometimes experienced in the more traditional low pressure system.