Although aliminum die casting has very widely applications. However some people still don’t know much about it. Especially for the person who may need aluminum die casting service, It will affect whether you can make the right decision. This post will discuss everything you need to know about aluminum die castings, it’s process, advantages, applications, and Aluminum die casting manufacturer recommended.
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What is Aluminum Die Casting
Aluminum die casting is the process of heating aluminum until it melts, then pouring the molten metal into steel casting molds (i.e., dies). After the material has cooled enough, it takes the shape of the mold inside and is taken out to be used or processed further. The final products have many advantages over parts and products made with other methods. Because of this, you can use them in many different industries and situations.
In die casting, you can combine two metals to produce a stronger version of the metal base. The most popular alloy used in die casting is aluminum. Alloys of aluminum are made by combining aluminum with one or more of a variety of other metals, such as copper, magnesium, silicon, or zinc. Depending on the type of product you’re making and whether or not it requires extreme durability or pliability, the ideal ratio of these other metals in aluminum alloys will vary.
Aluminum Die Casting Process
Aluminum die casting involves injecting molten aluminum into a steel die to produce aluminum parts of the desired design. The procedure usually entails the following steps:
Step 1: Preparing the Die
A steel alloy die is first created. A well-prepared die will allow for efficient filling and removal of the aluminum product. Each die has at least two components that are joined during casting and then disassembled after the aluminum product has cooled.
The more sophisticated dies will have several parts to make holes and other specific shapes. The cavity inside the die is filled with aluminum, which is injected through a hole in the die’s component. Even though dies can be used repeatedly, the number of times they can be used before they wear out is dependent on several factors, including the quality of the part being made, the alloy being used, and the design of the part itself.
The parts of the die are lubricated and clamped together after you are done creating them.
Step 2: Injecting the Aluminum
To fill the mold, molten aluminum is poured into the hole in the die. This is done under a lot of pressure so that the aluminum sticks quickly to all the details of the die. This step of the process takes only a few seconds.
Step 3: Allow the Aluminum to Cool Down
The die is held firmly in place while the aluminum cools after casting. Aluminum alloys are particularly useful because they solidify into a single, cohesive mass upon cooling, making for a durable end product.
Step 4: Removing the Formed Part
Unclamping the die after it has cooled reveals a product that has retained the exact shape of the die. In theory, this could be done thousands of times, allowing for the production of an infinite number of products.
The surface of the finished product is smooth. Most of the time, finished products don’t need much work to be done on them so they can move quickly to the delivery stage. Also, the die-cast mold is used again and again to make the same parts until it breaks. Because of this, aluminum die casting is a great way to make a lot of things at once. Die casting is the best way to make this, which is why it is popular in many industries.
The Advantages of Using Aluminum Die Casting
Aluminum die casting has some advantages over other metals, making it the best process for producing aluminum parts. We enumerated some of them below:
Can Make Parts with Complicated Designs
High-Pressure Aluminum Die Casting can be made in any size, shape, arrangement, or configuration you can think of. You can produce parts like small electrical parts that weigh less than a gram to transmission housings and automatic clutch housings.
Each part is made precisely to the design specifications, is free of flaws, and needs very little post-processing. High-Pressure Aluminum Die Casting has made it possible for engineers to produce parts with complicated shapes that will work as expected. Cast aluminum parts stay the same when they are put together, taken apart, fixed, or remade.
Produce High Quality Products Fast
Manufacturers of high-pressure die cast components are always looking for better, more time-saving methods of mass-producing their goods. Because of computer technology advancements, there is more pressure than ever to meet customer deadlines. High-Pressure Aluminum Die Casting can easily keep up with the ever-increasing demand for increased efficiency and productivity. You can produce components at a faster rate than with other alloys.
Compact Microstructure Parts and Good Tensile Strength
High-Pressure Aluminum Die Casting stands out from the rest because it has an unparalleled strength-to-weight ratio compared to other metals and alloys. Products made from aluminum have the strength of steel without the weight, making them ideal for the modern market. This also makes it ideal for applications that require it to withstand harsh environmental operating temperatures.
Products are of High Quality Finish
Die castings have a very smooth surface and can be made into various sizes. Most parts made with a die casting process have thinner walls and a smoother surface than those made with a sand casting process. Sand casting usually makes surfaces that are rougher than the others.
Each sector constantly searches for new ways to increase efficiency and cut costs without compromising quality. Companies opt for Aluminum Die Casting due to the process’s low cost, which allows for greater investment in research and development. The time savings and lack of final product are the primary causes of the financial benefits. Customers and consumers benefit from reduced material costs, shorter production times, and no rework.
Aluminum die casting produces corrosion-free products. It is a property of aluminum that many manufacturers like as the surface will oxidize when exposed to air. This attribute makes Aluminum castings long-lasting and dependable, which benefits customers because they get more use out of their purchases.
High Usage of Materials
Aluminum casting parts can be put together and used right away, or with only a small amount of machining. The material can be used 60–80% of the time, or even more, which is good for the economy. Because of high precision, less machining allowance, assembly without machining, or good surface quality, machining equipment and costs are reduced, and good economic benefits can be gained
Simpler Manufacturing Process
In automobile die casting, other inserts with special properties can be embedded into aluminum parts. You will not have any issues when it comes to meeting the service performance requirement. It will also shorten the time it takes to put things together and make the manufacturing process easier.
Aluminum Die Casting Applications
There are some great mechanical benefits to aluminum alloy. Because of this, they are being used in many applications. For instance, they are an important part of the construction and auto industries.
A report says that the aluminum casting market was worth $50.5 billion in 2019 and is expected to grow at 6.4% from 2000 to 2027. More businesses will join the community, and more applications will use them.
Some of the best uses of aluminum alloy die casting are listed below.
Aluminum can be found in roof beams, window frames, and other places. Die-cast aluminum parts are also used to build large structures like bridges and business buildings these days.
Aluminum alloys are light, which is another important quality for modern cars. Because of this, these alloys are used for many things in the automotive industry. They are in everything, from engine parts to body parts.
The electronic industry has grown more than any other industry over the past 20 years. These industries have been very good at developing new consumer product ideas. And aluminum has been a vital part of making these consumer goods.
Die-cast aluminum alloy is used in many things, from smartphones to the housing for 5G networks.
Aluminum is strong for how light it is, and it doesn’t rust or corrode. They are also not that expensive. So, an aluminum alloy is used in the furniture industry to make different types of home and office furniture.
Die-cast aluminum is used to make more and more chairs, for example. Many essential furniture parts, like door locks, knobs, hinges, and other fittings, are also made of aluminum
The aerospace industry, like the auto industry, needs an alloy that is both light and strong when hit. Also, the aerospace industry needs complicated tools and structural parts with high tensile strength. Because of this, different parts of an airplane are made from aluminum die-casting materials.
Die-cast aluminum is used to make some aerospace parts, like the heads of airplane engine pistons, housings for airplane distributor caps, housings for loading cargo, parts of lighting fixtures, parts of the fuel system, and detention ring parts for electronic enclosures.
The Most Frequently Used Alloys in Aluminum Die Casting
Manufacturers worldwide use die casting in producing parts in huge number because the process provides uniformity, accurate finished product designs, and high quality surface finishes. Die casting also help manufacturers to reduce or get rid of the post-producing machining.
This, in turn, cuts down on the time it takes to make something and makes the metal molding process much more cost-effective. But it might be harder to die cast stronger metals, like certain grades of Steel. This is why manufacturers prefer other ways to cast metals that are stronger.
Below are some of the most common alloys that are used by aluminum die casting companies.
Alloy A380 is the most popular casting alloy on the market, and it can be used for many applications. It doesn’t do well when it comes to resisting corrosion, so depending on what your final product will be used for, A380 may not be the best choice. This alloy flows well, doesn’t crack when heated, and seals well under pressure. It is utilized in producing various products like engine brackets, household furniture, hand tool, electronic equipment, and power.
A360 is much better at resisting corrosion because of its high silicon content and is used by many manufacturers. This alloy is strong enough to withstand high temperatures. It is harder to cast, but this problem can be worked around in many situations. The pressure tightness and fluidity of A360 alloy is quite impressive. Because of this, we recommend A360 for most industrial applications.
This alloy has a 99.0% or greater purity, it is also referred to as commercially pure aluminum. Among the common alloys it is considered as the softest. Some of its best characteristics are non-heat treatable, excellent corrosive resistance, and very malleable. 1100 aluminum has good weldability, but it has narrow melting range. It is frequently used for making heat insulators, lighting, electrical work, and license plates.
A383 is a common die-cast aluminum alloy that has more silicon and less copper. When compared to A380, this alloy has slightly better resistance to corrosion, resistance to hot cracking, fluidity, and strength at high temperatures.
Ideal for special applications that requires thermal conductivity, wear-resistance properties, and thermal conductivity.
Excellent resistance to corrosion, ability to be machined, polished, and anodized, but other qualities like pressure tightness, fluidity, and the ability to be cast are lost.
What's the difference between die casting and sand casting when it comes to using aluminum?
The material used to make the mold is the most important difference between die casting and sand casting. For aluminum casting, a mold made of aluminum alloy is used. In sand casting, on the other hand, a mold is made of sand.
Sand casting can make more complicated designs. On the other hand, aluminum die casting is faster and more accurate in terms of size. Another critical difference is that sand casting makes thicker walls, while aluminum die casting can make thinner walls. So, sand casting is not the best way to make small parts.
The speed of production is another vital difference between these two methods. Die casting tooling is a complicated job that takes a long time to do. On the other hand, making sand casting tools is easy and doesn’t take as long as die casting. Die casting is the best way to make a lot of parts, like if you need to make a thousand of them. But sand casting is the best way to make 100–150 units at a time.
When it comes to producing a huge number of parts, aluminum die casting is the most efficient and less expensive process. Aluminum is chosen over other metals. because it has qualities that make it stand out. For the company who need aluminum die casting service, finding a reliable & trusted Aluminum die casting company is very important.
Leisheng Machinery is a world leading Aluminum Die Casting manufacturer in China. Start to provide aluminum die casting service since 2006. If you want more details & requirements, contact us.