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Welcome to GC Precision Mould Co., Ltd, A China Aluminum Die Casting manufacturer, one-stop manufacturer that services aluminum die castings, zinc die castings, magnesium die castings, precision CNC machining, surface finishing, and assembly. Our team is an expert in those areas and can give tailored solutions to meet your specific needs. Besides of this, We can help with prototypes, and any other particular alloy materials that you may need such as 6061 and 6063 die casting parts.

We are not only to take your orders and deliver the items you have ordered from us. But also to assist you at every testing level of the process, during the design and development phase, we collaborate with you to ensure that we can implement the most inventive and creative ideas in the manufacturing of your products that meet your specifications and expectations. We can ensure that you will be satisfied with the final output and that your requirement will be addressed properly using this way.

Contact us right now to learn more about the services we provide and how we can help you achieve your project in goal.

Aluminium Die Casting | A Comprehensive Guide to its Process, Design Tips and Diverse Applications

 

The world is fast moving towards innovative and advanced technologies to make metal parts. Several industries demand highly accurate metal parts. Besides this, different industries value their money and time. So, aluminum die casting plays a very critical role in this domain. It is a fast, efficient, and durable process to convert the sheet metals into the required shape and design. So, in this article, we will discuss the aluminum die casting in detail. Besides this, we will talk about its process, design tips, suitable alloys, advantages, disadvantages, and surface finishing options available in the market.

Aluminum die casting is efficient and economical and offers a wide range of durable shapes and components. Little or no machining is required after a part is die-cast because the process provides very close tolerances for even complex shapes. Aluminum die castings can also be easily plated or finished. Aluminum die castings are dimensionally stable and heat-resistant.

How would you define aluminum die casting?

Aluminum die casting is a unique and popular process to convert sheet metals into the required geometry and shape. This process uses injecting molten aluminum alloy to manufacture the metal part. Then this molten aluminum is allowed to be inserted into the steel mold or die. This process takes place under high pressure. It is typically comprised of two halves. They are precisely machined to form the desired shape of the final product. Additionally, it has a wide scope of applications in several industries that require high accuracy and efficiency.

Step-by-Step Process of Aluminum Die Casting

The aluminum die casting process includes raw casting design with the die casting molds, finish production design involving post-machining, and other surface finishing such as electroplating, electrophoresis, painting, anodizing, and powder coating. Aluminum die-casting has found several applications across multiple industries. So, let’s discuss how aluminum die-casting works. Here is a complete description of each operation that takes place during this process.

 

Aluminum die casting alloy parts

1. Tooling Design

The first and foremost step in aluminum die casting is tooling design. This includes the production of the mold or dies. Then these dies determine the final shapes and features of the metal part. So, the tooling design undergoes multiple operations. Let’s discuss each process in detail.

aluminum die casting part analysis

 

  • Part Design Analysis: Before designing the tool for making metal parts, engineers must first analyze the dimensions and features of the metal part. It will help them identify the potential challenges. Besides this, it will ultimately refine the features of aluminum die-casting. This analysis may include checking the draft angles, wall thickness, and gating and venting locations.
  • Die or Mold Design: The second step is to design the mold or die once you analyze the metal part. Here, the engineers make a detailed plan for the manufacturing of metal dies. This plan may include different designs, i.e., designs of the cavity, cores, slides, and other features. So, all these considerations are necessary to form the desired parts.
  • Material Selection: Besides effective design, choosing the right material for your metal parts and molds is also very important. So, if we talk specifically about aluminum die casting, multiple materials can be used to make a die or a mold. The most common materials may include high-quality tool steels, i.e., H13 or P20. They have excellent hardness, wear assistance, and high thermal conductivity.

aluminum die casting pwoder coating

●    Mold or Die Manufacturing: After completely designing the sheet metal part and die, the next step comes. It includes the making of a die or mold. So, here, we can use high-precision machining techniques. The most common one includes milling, drilling, or EDM (Electrical Discharge Machining). Besides this, this is carried out with thorough inspection and high accuracy. 

die casting alloy parts

2. Melting and Injection

So, just after the manufacturing of the die, the aluminum die-casting process starts. The operators inject the aluminum alloy bars into a furnace. Then these bars undergo melting due to the high temperature inside the furnace. This temperature usually lies between 650°C and 700°C (1200°F and 1300°F). It is suitable for most aluminum alloys used in die casting. Just after this, the molten aluminum is allowed to fill the injection system. The injection system consists of a plunger or a hydraulic piston. It applies high pressure to push the molten metal into the die cavity. This is quite a fast process. Moreover, it is usually carried out within the speed limits, i.e., ranging from 10 to 100 m/s (30 to 300 ft/s).

die casting melting and feeding

3. Cooling and Solidification

 

Here, the molten aluminum enters the die cavity. Then it quickly cools and solidifies to take the specific shape of the mold or die cavity. Additionally, the cooling rate plays a significant role in the quality of the final part. So, the more rapid the cooling rate, the more it will lead to internal defects. These defects mainly include porosity. On the other hand, the slow cooling rate can lead to wrapping or distortion.

So, make sure to provide an optimal cooling rate during the aluminum die-casting process. Here, the die can be equipped with cooling channels. These channels control the water or coolant circulation. So, it will eventually help maintain the uniform temperature distribution in the die cavity. Thus, it provides consistent quality for metal parts.

4. Ejection

The aluminum die-casting machine usually has two halves. These halves have some separation inside them. A solidified aluminum part is ejected from the die cavity. This ejection takes place because of the ejection pins and ejector plates (the ejection system). They push the part out of the die cavity. This is important to properly eject the metal part. Otherwise, it may lead to damage to both the metal part and the die. Additionally, the ejector pins and ejector plates are designed properly. So, they provide a smooth and efficient ejection of metal parts without causing damage.

5. Trimming and Finishing

So, if the ejection is carried out efficiently, the next process is trimming and finishing the aluminum part. These processes give a final look to your metal part. They remove the extra material attached to the part, i.e., the flash. This gives a pleasant appeal to the metal part. Besides this, it also increases its efficiency. The trimming process can be carried out manually or automatically. It uses multiple pieces of equipment, like a trim press or CNC machining centers.

After trimming, the metal part undergoes finishing. This may include machining, polishing, coating, or plating. All these processes increase the performance and refine the appearance of metal parts. Besides this, the finishing operation may lead to tight tolerances. So, it eventually improves the surface quality. Moreover, it offers corrosion resistance or other functional properties based on the needs.

Different Aluminum Alloys Used in Aluminum Die Casting

Here is a detailed table that will help you know the different alloys, their compositions, and their applications in the diverse market.

Alloy

Composition

Properties

Applications

A380

Aluminum (Al): 8.5–9.5%, Silicon (Si): 2.5–3.5%, Copper (Cu): 3.0–4.0%, Iron (Fe): ≤1.3%, Magnesium (Mg): ≤0.1%, Manganese (Mn): ≤0.5%, Zinc (Zn): ≤0.5%, Titanium (Ti): ≤0.15%

  Excellent fluidity and pressure tightness

  Good mechanical properties

  Superior corrosion resistance

  Suitable for intricate and thin-walled parts

Automotive components (engine blocks, transmission cases), electronic housings, household appliances

A383

Aluminum (Al): 8.5–9.5%, Silicon (Si): 3.0–4.0%, Copper (Cu): ≤0.1%, Iron (Fe): ≤1.3%, Magnesium (Mg): ≤0.1%, Manganese (Mn): ≤0.5%, Zinc (Zn): 0.1–0.5%, Titanium (Ti): ≤0.15%

  Higher strength and hardness compared to A380

  Good fluidity and pressure tightness

  Excellent corrosion resistance

Automotive components (brackets, brackets, housings), electrical enclosures, consumer products

A360

Aluminum (Al): 8.5–9.5%, Silicon (Si): 0.7–1.3%, Copper (Cu): ≤0.1%, Iron (Fe): ≤0.35%, Magnesium (Mg): ≤0.1%, Manganese (Mn): ≤0.5%, Zinc (Zn): 0.35–0.6%, Titanium (Ti): ≤0.15%

  High strength and ductility

  Excellent pressure tightness

  Good resistance to hot cracking

Automotive components (brackets, engine parts), aerospace components, electrical connectors

ADC12

Aluminum (Al): 10.5–13.0%,

Silicon (Si): 0.3–0.6%, Copper (Cu): ≤1.5%, Iron (Fe): ≤1.3%, Magnesium (Mg): ≤0.3%, Manganese (Mn): ≤0.5%, Zinc (Zn): ≤1.0%, Titanium (Ti): ≤0.15%

  Excellent castability and fluidity

  Good strength and hardness

  Superior corrosion resistance

Automotive parts (engine mounts, brackets, wheels), industrial machinery components

A413

Aluminum (Al): 11.0–13.0%, Silicon (Si): ≤0.6%, Copper (Cu): ≤0.1%, Iron (Fe): ≤0.5%, Magnesium (Mg): ≤0.1%, Manganese (Mn): ≤0.35%, Zinc (Zn): ≤1.0%, Titanium (Ti): ≤0.15%

  Good castability and fluidity

  High strength and hardness

  Excellent corrosion resistance

Aerospace components, automotive parts, consumer products

Effective Design Tips for Aluminum Die Casting

Here are some effective tips to improve the overall efficiency of Aluminum DIe-casting processes

Design Consideration

Description

Simplified Drawings

Select the right alloy

Choose an alloy based on strength, corrosion resistance, and machinability.

Maintain uniform thickness

Keep walls 2-5mm thick for even cooling and fewer defects.

Use generous fillets

Rounded corners reduce stress and improve flow during casting.

Minimize machining

Design for near-net shape to reduce secondary operations.

Optimize draft angles

Include 1-2 degrees draft angle per side for easy ejection from the mold.

Minimize part complexity

Simplify designs to lower manufacturing costs and defects.

Avoid sharp corners

Use rounded edges to prevent stress concentrations and improve flow.

Design for uniform cooling

Ensure even cooling to minimize warping and distortion.

Opt for thin cross-sections

Thin sections promote faster cooling and reduce material usage.

Account for shrinkage

Design with allowances for aluminum’s natural shrinkage during cooling.

Add ribs for reinforcement

Reinforce areas requiring extra strength with ribs or gussets.

Balance wall thickness

Maintain consistent thickness to prevent defects and warping.

Incorporate bosses for features

Use bosses to facilitate the mounting or attachment of components.

 

What are the Pros of Aluminum die-casting

Aluminum die-casting offers several benefits. Let’s discuss these benefits in detail.

CNC machining service

1. Complex Geometries

Aluminum die casting is quite an efficient process to cater to the production of complex part geometries. They provide high precision and consistency throughout the whole operation. Additionally, it has a wide scope of applications dealing with components with complex details or thin walls.

2. High Production Efficiency

Aluminum die-casting provides high production rates. It allows the rapid manufacturing of large quantities. This may also include the manufacturing of parts with fewer post-processing requirements. Moreover, its efficiency helps minimize production lead times and overall costs.

3. Lightweight

As we know, aluminum is lighter in weight. This property makes it ideal for applications. This process is widely used where weight reduction is important. These industries may include the automotive and aerospace industries. Additionally, the die-cast aluminum parts are capable of excellent strength and durability.

4. Excellent thermal conductivity

Aluminum has excellent thermal conductivity. That is why it is the best go-to option for multiple applications that require heat dissipation or thermal management. These may include heat sinks for electronic devices. Besides this, it is also used in engine components in automotive applications.

5. Corrosion Resistance

The aluminum die-casting is compatible with various aluminum alloys. These alloys generally have good corrosion resistance. So, it ultimately increases the durability and longevity of die-cast parts. Moreover, they have wide applications in making metal parts that are particularly used in outdoor or corrosive environments.

6. Recyclability

The most important feature of aluminum die-casting products is that they are highly recyclable. If the metal parts get some scrap or defective parts, they can easily melt down and then be reused in the production process. So, this sustainability aspect gives aluminum die casting an environmentally friendly manufacturing option.

What are the cons of aluminum die-casting?

So, let’s discuss the drawbacks of aluminum die casting in detail.

1. High Initial Tooling Cost

Every complex part and its geometry need special tooling; this process offers a significant upfront cost of tooling. It is also expensive when dealing with large production volumes. Besides this, the initial investment is also suitable for small-scale or low-volume production runs.

2. Limited Material Options

Aluminum die casting is generally restricted to aluminum alloys. This limits the overall choice of materials compared to other casting processes. Moreover, aluminum alloys have a wide range of properties. So, they have specific applications in different industries.

3. Porosity and Defects

Different cooling rates may lead to improper process control. Consequently, it leads to the formation of shrinkage or other defects in die-cast aluminum parts. So, fixing these issues needs additional post-processing steps. They may include machining or surface treatments, increasing production costs.

4. Dimensional Variation

Die casting may result in dimensional variation between parts. It is generally because of different factors. These factors may include shrinkage, thermal expansion, or contraction. Besides this, tight tolerances may require additional machining or secondary operations.

5. Design Limitations

Although aluminum die-casting offers different design flexibility, it does not support certain design features. They may include sharp corners or undercuts. These are relevantly challenging to achieve. Besides this, they need additional tooling considerations.

Diverse Applications of Sheet Metal Die-Casting

It has a wide scope of applications in different industries. Let’s discuss it in detail.

  1. Automotive Industry: It is mainly used in the automotive sector for producing components, i.e., body panels, chassis parts, brackets, and structural reinforcements.
  2. Aerospace and Aviation: It is widely used in manufacturing aircraft components. These may include fuselage panels, wing skins, structural ribs, and interior fixtures.
  3. Consumer Goods: Aluminum die casting is widely used in making consumer goods, i.e., kitchen appliances, home furnishings, and consumer electronics.
  4. Medical Equipment: In the medical sector, it is widely used for fabricating equipment enclosures, instrument panels, trays, and components for medical devices.

Why choose ALU Die Casting?

ALU is the leading company for aluminum die casting in China. We offer numerous advantages for providing high production efficiency. We are experts in dealing with lightweight yet durable parts. Our facility is equipped with advanced and modern technology to cater to all your needs. Besides this, we have a team of experts that can deal with simple and large production volumes within time. If you are looking for an exclusive die-casting process, contact us now!

Conclusion

In conclusion, aluminum die casting is now becoming popular because of its flexibility in dealing with complex parts. It uses molten aluminum alloy and injects it into the die cavity. Then it is allowed to solidify. The aluminum metal gets the shape of a mold or die. This process offers multiple advantages. Besides this, the parts produced during this process can easily be recycled by melting down the metal part again in the furnace. It has a wide scope of applications in different industries, i.e., automotive, aerospace, medical industry, and military defense equipment.

Frequently Asked Questions

Q1. What benefits does aluminum die casting offer?

A: Aluminum die casting provides multiple benefits. They may include high-dimensional accuracy, complex part geometries, rapid production rates, etc.

Q2. Can aluminum die casting be used for high-volume production?

A: Absolutely yes, it is used to make high-volume production. So, it has a fast cycle time. Besides this, it is used to produce consistent and high-quality parts.

Q3. What are common defects encountered in aluminum die casting, and how can they be minimized?

A: There are various common defects encountered during the die-casting process. This may include porosity, shrinkage, and surface defects. So, these can be minimized through proper design, process optimization, and quality control measures.

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About Us

Established in 1999, GC Precision Mold Co. ltd (Was Aluminium die casting manufacturer (China) Limited ), is now becoming one of the leading global suppliers of high quality die casting parts and machining of nonferrous metal products.

Our production line include but not limited to aluminium die casting, zinc die casting, bronze sand casting, aluminum gravity casting, CNC precision machining. our products were recognized and certified by ISO 9001, we always ready to be your trusted partner and supplier in China.

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