What is the quantity level for conversion to a die casting from other casting?

Yes, no, maybe. (See other list)

Hello friend;

An automobile company should already have the process fully developed... anyway, here you go, use this tables as a start.

Here is a good source of info...

http://www.diecasting.org/faq/

A lot depends on your quantity and how much machining can be eliminated. There is also a case for Permanent Molding where a higher strength and closer tolerance can be maintained than with sand castings when it comes to automotive castings.

In general:

Sand castings: lowest equipment, cost highest part, cost most machining needed to complete. High strength, good soundness and good ductility depending on alloy and heat treatment.

Permanent Mold: higher equipment cost, lower part cost, somewhat near net shape though the use of shell cores or core pins. Higher strength, good soundness and better ductility depending on alloy and heat treatment.

Investment casting: Higher to equal equipment cost to PM, higher cost than sand or permanent mold, high strength, good soundness and ductility, near net shape eliminates most machining needs.

Die Casting: highest equipment cost, lowest part cost, possibly eliminates a lot of machining though the use of pull pieces and core pins. High strength, inherent porosity and lowest ductility.

Any "economic quality level" is dependent or the size, configuration, alloy, mechanical (physical) requirements and required machining in order to determine.

Thanks for sharing Information

Here is a link from the American Foundry Society that might be of some help.

http://www.metalcastingvirtuallibrary.com/afscaps/caps.aspx

Please tell us endurance, our newest spammer buddy...

What automobile company do you work for that makes their own parts and has no engineers on staff?

Well,

On the one hand, if you were going from, say, what some may think is without a doubt the premier casting method that would be considered the absolute lower reaches of the once only dreamed of plateau of post-modern quasi print-in-place, a once only dreamed of technology whose origins go back many years, itself now arguably the far reaching leap into the next century's vast reaches of untold many miracles to be beheld by the beholder.

On the other hand, well, you get the jist..................