Zinc alloys are used in making precision parts such as sprockets, gears, and connector housings. Copper alloys are used in plumbing, electrical and marine applications where corrosion and wear resistance is important. Minimum wall thicknesses and minimum draft angles for die casting are Material Min. Large castings tend to have greater porosity problems, due to entrapped air, and the melt solidifying before it gets to the furthest extremities of the die-cast cavity. The porosity problem can be somewhat overcome by vacuum die casting From a design point of view, it is best to design parts with uniform wall thicknesses and cores of simple shapes.
Heavy sections cause cooling problems, trapped gases causing porosity.
All corners should be radiused generously to avoid stress concentration.