5 Things about Aluminum Die Casting

Aluminum die casting is a process used to make complex aluminum components. This metal-forming process involves heated ingots of aluminum to high temperatures. This process involves pouring molten aluminum into a steel die, which is a mold. After the aluminum has solidified, the two halves are separated to reveal the finished product. The resulting product is formed with a smooth surface and can be quickly replicated using the same mold. This process can be used for the production of large volumes of components.

1. Aluminum Die Casting's Advantages

Compared to other metal-forming processes, die casting aluminum offers numerous advantages. One of the main advantages of die casting is its ability to produce complex shapes that are not typically produced through other processes. For instance, in the production of complex components such as transmissions and engine blocks, such as die casting can produce these parts at tight tolerances. Additional advantages include the ability to have textured or smooth surfaces and the capacity to accommodate both large and small parts. Learn More.

2. Considerations of Aluminum Die Casting Part Design

Various aluminum parts produced by high pressure die casting, A few considerations have to be taken into account when designing the part to be cast. One of these considerations is the mold design, which is designed to separate the solid part from the mold. The parting line is a line that marks the area where the parts will come out. One of these is the location of the injection points. Having multiple injection points can help avoid the molten metal from settling in the die. One of these considerations is the presence of cavities in the design. This can help prevent the part from coming off completely when the mold is separated. One of these considerations is the thickness of the part's walls. Since there are no guidelines on this matter, it is usually preferred to have walls with consistent thickness.

3. Comparison to Green Sand and Permanent Mold Casting

Alternative casting processes such as green sand and permanent mold are commonly used to make aluminum components. Compared to the other two, green sand processes use less expensive materials to create the mold. Permanent mold casting involves pouring molten aluminum into a mold. This process produces stronger and more complex casts. Compared to the other processes, die casting produces better-quality components and less surface treatment.

4. Machining and Finishing Options

Most die cast aluminum components require minimal machining to achieve a good surface finish. However, there are also various finishing options available. Some of these include orbital, orbital, and selective metal finishing. Shot peening is a commonly used method to improve the fatigue resistance of die cast aluminum components. A protective coating or a powder coat can also be applied to the finished part.

5. The Most Common Aluminum Die Casting Alloys

Among the most popular aluminum alloys used in die casting are A380, B390, CC401, and A413. For instance, A360 is a high-performing aluminum alloy that exhibits excellent corrosion resistance and pressure tightness. B390, on the other hand, has the lowest ductility of all cast aluminum components. One of the most commonly used aluminum alloy for die casting is A380. This type of metal is ideal for various applications due to its combination of properties and casting.

Conclusion

Depending on the complexity of your project and the budget you have, die casting may be an expensive process. However, it is usually worth it if you need a large number of parts.

At TEAM MFG, we offer a full range of aluminum die casting services that include design and die design. Our facility is ISO certified and has the necessary equipment and processes to produce high-quality components. Contact us today!