Occupational Exposure to Die-Casting Metal Emissions

Die-Casting Defined

Whether creating a smartwatch or car part, pipe fitting or stethoscope, airplane engine or golf club, die-casting is a crucial step in the making of these – and thousands of other – everyday objects.

Die-casting is a metal process that uses high pressure to force liquefied metal into a mold (die) cavity to produce complex shapes. The dies are made of high-quality metal and allow manufacturers to mass-produce intricate objects and designs with great precision.

Die-casting is a necessary part of modern manufacturing and requires skilled workers to perform with proficiency and dedication day after day. The job is not without risks. Die-casting can pose serious occupational health hazards if a clean and safe indoor air quality is not established and maintained.

The types of metal items that can be die-casted are endless, but the steps to perform it are generally as follows:

Step 1: Die Prep: Typically made of steel, a mold is prepped with a lubricating agent to ensure the cast part is released without compromising the structure

Step 2: Metal Prep: The metal is melted using a furnace, then poured into a ladle

Step 3, Metal Injection: The molten metal is poured into the hot chamber, then injected into the die mold using high pressure

Step 4: Cooling: The die cools until solidified in the shape of the mold

Step 5: Ejection: Once completely solid, the part is removed from the mold

Step 6: Trimming: Any excess metal is trimmed from the product

Health Problems

As with any modern industrial manufacturing hot work, die-casting can cause illness due to metal dust and fume emissions that occur during the process. Zinc, aluminum, magnesium, copper, lead, etc. are used and all have the potential to make workers sick if countermeasures are not taken to protect them.

According to OSHA, even one-time exposure to certain metal fumes can cause symptoms such as upper respiratory irritation, confusion, headache, dizziness, and nausea.

Long-term exposure may cause damage to the lungs, kidneys, and central nervous system. Furthermore, inhalation of the most dangerous fumes can pose serious risks, like pulmonary and respiratory disease, even cancer.

The Clean Air Solution

In order to truly protect a laborer from toxic fumes emitted during the die-casting process, employers should do the following:

1. Employ a thorough risk assessment and identify specific health hazards associated with die-casting emissions
2. Require workers to wear protective clothing, including breathing masks, if necessary
3. Ensure that control measures, such as proper ventilation, are in place
4. Install air cleaning equipment, such as source capture and fume extraction products

At AIRSInc, we serve our metalworks customers by providing IAQ management solutions, which include products such as our SP-4000BWC Portable Air Cleaner.

Contact us today for a free air quality assessment with one of our skilled and experienced indoor environmental specialists.