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What is Aluminum Die Casting?

Aluminum die casting is a manufacturing process which allows to produce complex aluminum parts with smooth and textured-surfaced accurately. In Aluminum die casing, ingots of aluminum are heated by high temperature until they are completely molten. The liquid aluminum is injected into the cavity of a steel die which is known as a mold by high pressure. The die is made up of two halves. When the molten aluminum is solidified, they are separated to reveal the aluminum casting parts. Aluminum die casting parts are produced with a smooth surface and request less and even no machining processes. Aluminum die casting process can be repeated many times by the same mold before damaged. Aluminum die casting is an ideal manufacturing process to produce aluminum parts in high-volume. Aluminum die casting parts are corrosion resistant, highly conductive and have a good stiffness and strength-to-weight ratio. Aluminum die casting allows to produce aluminum die casting parts in high volume very quickly. Compared to other alternative casting processes, aluminum die casing is more cost-effective.


Aluminum die casting alloys are lightweight. It as high dimensional stability for parts with complex geometries and thin walls. Aluminum is able to withstand good corrosion resistance and mechanical properties. Aluminum has high thermal and electrical conductivity. So, it is a good alloy for die casting. Low density aluminum is important to die casting industry.

Aluminum Die Casting


What is aluminum die casting process?

Aluminum die casting process uses a steel mold which is able to produce ten of thousands of casting parts rapidly. The die is made two sections to allow the castings to remove. The casting cycles starts with two die halves which are clamped together by the die casting press. Molten aluminum is injected in the die cavity and solidify quickly. The two sections are mounted in a machine and are arranged so one is stationary when the other is moveable. The die halves are drawn apart and the casting is ejected. Depending on the complexity of the casting, dies can be simple, complex, having moveable slides cores.


What are the advantages of aluminum die casting?

Aluminum is the most widely used cast metal in the world. It provides many advantages over other pressure die casting process which make it a suitable choice to produce aluminum parts. Aluminum die casting is able to produce complex shapes which neither extrusion nor machining can effectively produce. For example, complex automotive part such as transmission and engines blocks. Aluminum die casting allows to produce parts with textured or smooth surfaces. It can produce small and large parts. Aluminum is a lightweight metal. It can produce very light weight aluminum parts without sacrificing strength. Aluminum die casting offers many surface finishing options. Compared to other metal material, aluminum can withstand higher temperatures. Aluminum die casing parts are corrosion resistant, high conductive. They have a good stiffness and strength-to-weight ratio. Compared to other casting processes, aluminum die casting allows to produce die casing parts in a high volume more quickly and more cost-effectively. Aluminum die casting is lightweight and durable. It has good strength-to-weight ratio. Aluminum is resistant to corrosion. Aluminum die casting has excellent electrical conductivity. Aluminum is recyclable and reusable.


What are the disadvantages of aluminum die casting?

1. Aluminum die casting parts have low hardness. They have poor wear resistance.

2. When in solidification, the volume shrinkage of aluminum die casting parts is large, it is around 6.6%.

3. The linear expansion coefficient of aluminum die casting part is high.

4. Aluminum is easy to stick mold. It needs to control the iron content strictly in the range of 0.8%-0.9%.

5. Aluminum has low melting point. So, it is limited when using under high temperature.


What are the most common aluminum die casting alloys?

The most commonly used aluminum die casting alloys include A380, 383, b390, A413, a360 and CC401. When you choose the right alloys, the most important thing is to consider your intended application. A360 is good corrosion resistant, pressure tight and very fluidized when molten. B390 is widely used for applications like automotive engine blocks as it has great wear resistance, high hardness and have the lowest ductility. A380 provides a good combination of casting and product properties.


What are the options for aluminum die casting machining and finishing?

Aluminum Die Casting Parts need minimal machining. There are many options for surface finishing. Aluminum die casting parts have a good surface finish by casting standards. Rough surface and other surface finish can be done by sanding, sandblasting or orbital sanding. Shot peening is a process to improve aluminum die casting parts’ fatigue resistance. A powder coat and other protective or decorative coating can be applied.


What is the application of aluminum die casting?

Aluminum can replace bronzed for low and medium speed and medium temperature heavy duty bearings. The cost of aluminum is around 50% cheaper than bronze. Aluminum can be used to produce mold. Aluminum is widely used to make bearing, pipe joints, pulleys and impacted and worn castings. Applications of aluminum die casting in military, automotive, engineering construction, power, electronics, computers, ships, household appliances, aerospace and other industries.


What is the difference between aluminum die casting and aluminum alloy die casting?

There are many things in our daily life are aluminum die casting parts. For example, cats, streetlight, mobile phones and more. There is just one word different between aluminum die casting and aluminum alloy die casting. But actually, they are different. The differences between them are their performance characteristics, application range and production advantages.


For aluminum die casting. Aluminum is the main raw material.

When the aluminum is headed to liquid, it is injected into the mold. As aluminum has great liquidity and plasticity, it is widely used in die casting industry. Aluminum die casting parts have perfect appearance. Aluminum die casting parts are inexpensive. The production cost of aluminum die casting parts is reduced, and wealthier for manufacturer.


For aluminum alloy die casting, alloy and aluminum are the main materials.

Aluminum alloy die casting parts have good iuster. Aluminum alloy die casting parts need polishing processing. During polishing process, nitric acid will be applied which can inhibit the corrosion and improve the brightness. Aluminum alloy die casting parts have good flatness and light effect. Aluminum alloy die casting is an important part of mechanical pats which is usually used in electronics, motor and other industries.


Today, the metal producing process which you choose depends on your budget, quantity and the purpose of your aluminum parts. Although die casting is an expensive process, it is still worthy if you want create part with high complexity in a high volume. TEAM Rapid provide high quality aluminum die casting services to ensure all aluminum die casting parts with excellent quality and consistent properties. If you want to learn more about aluminum die casting and need help with your projects, contact us today.

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