Die-casting, by definition, is a process in which molten metal is injected into metallic molds under pressure to form objects. The molds, which are generally made of steel and referred to as "dies", can be designed to create very detailed parts with little or no post-machining required after production. Die-casting is similar in many ways to plastic injection molding. Dies can be reused multiple times because the temperatures of the molten metal are not high enough to affect the steel die. Die-cast parts are generally lightweight, and for this reason are often used in aircraft and automobile applications.
History of the Die-Casting Process
Die-casting by pouring molten metal into a die, also known as the gravity pressure method, is a manufacturing method that has been used for hundreds of years. The more modern method of pressure injection die-casting was patented in the mid-1800's to create lead printer's type. The use of die-casting as a manufacturing technique exploded in the early 1900's, particularly when zinc and aluminum alloys became more readily available. Today, die-casting is a process used for a wide range of products and applications.
Materials Used in Die-Casting
In order to preserve the integrity of the die and allow it to be used for many castings, only alloys with relatively low melting temperatures can be used in the die casting process. Historically, lead and tin were the primary materials for die-cast parts, since they could easily be melted using conventional processes. Today, the majority of die-cast parts are created from aluminum or zinc alloys, but other metals such as magnesium or copper can be used. Each alloy delivers its own benefits, and therefore the product requirements drive the material choice. Aluminum can be found in aircraft and automobile parts, while copper may be used for parts that must conduct electricity.
Description of the Die-Casting Process
Before casting is performed, the mold is assembled. A mold can consist of two or more parts, depending on the complexity of the part being fabricated. Die-casting machines are categorized as either cold chamber machines or hot chamber machines. In a cold chamber machine, the molten metal is poured into a "cold" cylinder that is attached to the die. A hydraulic piston seals the cylinder and forces the metal into the die. In a hot chamber machine, the injection system sits in a bath of molten metal. A plunger is raised to pull molten metal into the injection chamber, and then pushed to inject the molten metal into the die. The mechanism of a hot chamber machine is much like a pneumatic bicycle pump, which pulls air in from around the pump and injects it into a tire through the tube and fitting.
After the casting process, the part may have flash or thin metal around the part where the two halves of the die come together around it. The flash is removed during post-machining processes. Some die-cast parts are plated or painted after manufacture for appearance, but the surface of die-cast parts are generally very smooth and hold fine detail.
Examples of Die-Cast Components
Many plumbing fixtures, such as bathtub spouts are manufactured from zinc alloys using a die-casting process and then plated with a chrome coating. Lightweight aircraft components can be die-cast from aluminum alloys. Other examples include heat sinks with complex shapes and large surface areas for electronic components, lightweight aluminum automobile parts, and lighting fixtures. Die-cast parts require very little post-manufacturing machining, saving time and labor costs in the manufacturing process.
Die-casting is a manufacturing process used for a variety of applications, including toys. In the Napoleonic era, gravity pressure methods were used to cast lead military figures. Die-cast vehicles have been available nearly as long as the vehicles themselves have existed. Early die cast manufacturers existing at the turn of the 20th century include Meccano in the United Kingdom and Dowst Brothers in the United States. Companies such as Ertl have been producing die-cast farm vehicles since 1945.
Volkswagen, the German car manufacturer based in Wolfsburg, Germany, has been building cars since the 1930s. While some models have become cult classics, this devotion to the brand also extends to die-cast replicas. Die-cast replicas of the the Beetle, Microbus, and other models have generated a dedicated following of collectors.
History of Volkswagen Replicas like many die-cast replica products, early replicas were produced primarily as children's toys. Wiking marketed 1:40 scale beetles, transporters and pickup truck replicas in the 1950s. Corgi followed in the 1960s with a wide range of Volkswagen vehicle replicas. Taiyo and the EF White Co. also produced model toys in the 1960's. Not many of these older replicas and toys are still available on the market, and when they do appear, they can command a hefty price at auction. A Hot Wheels 1969 Beach Bomb replica, of which only 25 are known to exist, was sold for a record $72,000 at auction in 2000.
Most Popular Replica Models the Beetle and the Microbus are by far the most prolific models in die-cast circles. For over 40 years, these two models have been replicated in die-cast form by many manufacturers in a huge range of standard and customized formats. While most of the other models are represented in die-cast replica manufacturers' product lines, they do not match the scope of replicas available for these two models. This is not surprising, given the cult following of the Beetle and the Microbus in full-size form beginning in the 1960s and continuing to the present day. Manufacturers of Volkswagen Replicas over the years, several manufacturers have produced replicas of Volkswagen vehicle models. Some of these manufacturers include:
Revel Germany - Revell Germany, most known for their plastic model kits, also currently has a popular line of ready-made 1/18 scale die-cast vehicles, including several Volkswagen models. In addition to the standard Beetle and Microbus models, Revell also manufactures some older Volkswagen models, such as the Karmann-Ghia.
Jada Toys - Jada produces standard replicas of a wide range of models, as well as customized models in both 1/24 and 1/64 scales.
Corgi Toys - Corgi Toys manufactured a few models in the late 1950s and through the 1960s.
Hot Wheels - A beetle model was one of the first Hot Wheels products in 1968. Hot Wheels continues to manufacture a variety of 1/64 scale Volkswagen replicas.
Micro-Machines - Micro-Machines released a line of Volkswagen replicas in the late 1980s through the 1990s. Micro-Machine models are slightly larger than N-scale models, which range from 1/148 to 1/160.
Maisto - Maisto manufactures a line of VW replicas, but the quality of their models and the vehicle detail are lower than those of other manufacturers.
Volkswagen die-cast replicas continue to be a popular choice for collectors in a variety of scales. Manufacturers are taking advantage of the popularity by continuing to maintain product lines that contain Volkswagen models, particularly the Beetle and Microbus.
Edward Fisher has sinced written about articles on various topics from Trucks, Travel and Leisure. I am a small business owner who sold and is now semi retired, spending time with my wife and spare time at my computer chasing another dream. I became interested in Die-Cast Products as a kid. Now that I am semi retired I am again chasing one of my pass. Edward Fisher's top article generates over 1000 views. to your Favourites.