Aluminum Die Casting: Ultimate Guide

Aluminum has special physical and chemical properties, not only light weight, strong texture, corrosion resistance, and has good ductility, electrical conductivity, thermal conductivity, heat resistance and resistance to nuclear radiation, is the development of the national economy of the important basic raw materials, aluminum and aluminum alloys are widely used in various industries.

If you are considering aluminum die casting for your upcoming projects and want to learn about this process in detail, read the guide below.

What is Aluminum Die Casting?

Aluminum die casting manufactures lightweight aluminum components that have complex shapes and thin walls.

Aluminum has the ability to withstand corrosion resistance, and it even offers high electrical and thermal conductivity. It is a process that helps retain the strength of aluminum die-casted components even at extreme temperatures.

The aluminum die-casting process has been used for a long time, and the first aluminum die-casting was done in 1800 using pressure injection. In 1849, the first machine for die casting was manufactured. However, it was manually operated.

After 20 years, the development of that die casting printer was enhanced. It was used for different components manufactured in high volume by 1900.

How Does It Work?

The process of aluminum die casting is carried out in multiple steps, and these are as follows:

• Aluminum bars are first heated at high temperatures until they melt. At the same time, a cold chamber setup is also used to avoid machine damage.
• The molten aluminum is kept in a melting pot away from the casting machine. It is then ladled from the pot into the die of the machine under high pressure.
• The aluminum in liquid form, after melting, is injected into the mold, and until solidified, it is left to rest.
• The two halves of the die are separated to eject the solidified aluminum component.
• The aluminum die-cast components might need the additional process of finishing so that the required surface finish is achieved.

Advantages of Aluminum Die Casting

The process of aluminum die casting is opted for because of the benefits it offers. Some of these benefits are as follows:

• This process manufactures components that have a smooth surface finish.
• It offers excellent tensile strength, and the cost of raw materials is low.
• The molecular structure of the components manufactured through die casting is firm and doesn't get cracks under pressure.
• It offers a thickness accuracy of less than 1.5.
• It offers durability and can produce complex shapes.
• The chemical and mechanical properties of aluminum die-casted components are excellent.

Types of Aluminum are Used for Die Casting

The aluminum alloys commonly used for die casting are the following:

• A390
• A380
• A413
• A360
• ADC-1
• ADC-12

The most important part of aluminum die casting is picking the right aluminum alloy. The A390 alloy offers excellent resistance against wear and is hard, but it is less flexible too. It can be used for engine blocks in automobiles.

A360, on the other hand, has excellent corrosion resistance and pressure tightness. When in the molten form, they are highly fluid and opted for oil pans of cars, 5G communication boxes, etc.

A380 alloy has seamless casting properties, and it can be used for household furniture and power tools.

Surface Finish Options for Die-Cast Aluminum

Die-cast aluminum can be treated with various surface finishing processes, and these are the following:

Anodizing

Anodizing is a cost-effective process that enhances the corrosion resistance of the components that are manufactured using aluminum die casting. It even enhances the durability of the components and adds a protective layer that is non-conductive.

Aluminum anodizing is used to build an oxide layer, which makes it non-conductive. Hence, it is suitable for applications where electrical conductivity is not needed.

Powder Coating

Powder coating is one of the widely opted processes for finishing the surface of aluminum components, which are manufactured through die casting.

This process is conducted in high temperature conditions and enhances the scratch resistance of the components. This process allows for having different gloss finishes, textures, and colors on the components.

Chem Film

Chem film is applied using various methods like dipping the component, brushing, or spraying. It offers high electrical conductivity to the aluminum die-casting components.

Applications of Aluminum Casting Parts

The aluminum die-casting components are widely used in many applications, and some of these applications are as follows:

Construction

In the construction industry, aluminum die casting helps manufacture frames for windows and roof structures. It is very commonly used in commercial buildings and bridges.

Automobile

Aluminum alloys are high strength, and their weight is less, which makes them fuel-efficient when used in vehicles. Hence, the automobile industry uses these alloys in various applications ranging from body parts to the engine of the car.

Electronics Industry

Aluminum plays a vital role in manufacturing electronics with innovation. These electronics are produced using die-cast aluminum, which can be used in 5G network housing and smartphones.

Furniture

The furniture industry uses aluminum due to its high strength, low weight, and ability to resist corrosion. The components are low-cost and, hence, can be easily used for affordable furniture.

Chairs, locks, knobs, and other fittings in the furniture industry are manufactured using aluminum die-casted components.

Factors to Consider in the Design of Aluminum Die Casting Parts

When designing components using the process of aluminum casting, some of the factors that should be considered are as follows:

Design of Mold

The design of the mold needs to be perfect and efficient so that the aluminum parts come out perfectly. The mold has a parting line that divides it into two halves, and this should be considered when creating the components.

Injection Point Location

When the molten aluminum is injected into the mold, the point of injection must be carefully considered. It should be poured accurately, ensuring that it fills the cavity property because sometimes the solidification of metal takes place very quickly, leading to uneven texture.

Thickness of Wall

The thickness of the wall component is also very important to consider. It is important that you go for a consistent thickness which ensures uniformity in the component.

Conclusion

The guide above has all the important details regarding aluminum die casting. You can now start your project keeping in mind all these aspects and how you can have a seamless aluminum component.

Start Your Custom Aluminum Die Casting Prototypes and Parts with DEK

If you are looking for help in your aluminum die-casting project, we at DEK can assist you. We have years of experience manufacturing aluminum components using die-casting processes.

We also ensure that we provide you with custom components based on your specifications. So, get in touch with us today and help us cater your projects.