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Aluminum Die Casting

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Definition of Aluminum Die Casting

 

Aluminum Die Casting is:A manufacturing process that produces accurately, defined, smooth and textured-surfaced metal parts. Accomplished by forcing molten metals into a mold form due to high-pressure systems.

What are benefits of Aluminum Die Casting

Strength

One of the most notable characteristics of aluminum cast parts is their strength to weight ratio, which exceeds any other metal or alloy. Aluminum products are lightweight but have the strength of steel. This factor adds to their endurance and life expectancy, a crucial factor for 21st Century products.

Appearance

Though aluminum castings are exceptionally strong and lightweight, they have a very positive appearance and aesthetic value. There are several uses for aluminum casting that do not require them to be seen or have a pleasant appearance. In applications where they have to perform and be appealing, they do not have to be adjusted or re-engineered.

Corrosion Resistance

When aluminum castings are exposed to the air, their surface becomes oxidized, which is a characteristic of the metal. This one factor is the reason that aluminum castings have longevity and reliability. This enhanced lifetime provides users with greater value.

Wide range of uses

We offer a variety of transmission components, including sprockets, roller chains, gears, couplings, racks, hubs, pulleys, taper sleeves, bearing seats, and more.

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Why choose us
1

Company technical strength

Company has advanced die-casting equipment and injection molding equipment, as well as a relatively complete enterprise management model. Our technicians can provide technical support in all aspects from product design, material selection to processing technology.

2

Product design

At MNW, you can choose the die-casting or injection molding process according to the size and shape of the parts you want. Our engineers give professional advice on materials, precision, and shell shape during design, and conduct simulations and tests.

3

Quality Management

The production of die-casting and injection-molded parts undergoes strict quality inspection, and a strict quality management system ensures stable and reliable product quality, meeting customer needs and industry standards. It has been widely recognized and praised by customers.

4

Supporting services

Offers a complete assembly capability, including manual and automatic assembly lines, to meet customers' needs. There is also online assembly testing and verification, committed to the goal of zero defect products, and continuous strict and reasonable process management.

 

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Aluminum Die-Casting Advantages

Aluminum casting has extensive surface finish options. The dimensional stability is another big advantage of the aluminum die casting process. Moreover, they are versatile, and you can use them for nearly any industry.
Here we have listed some of the benefits of aluminum casting:
Finished products with excellent surface finish
Good Tensile strength
Low-cost raw materials
Reduction of porosity and impurities
The firm molecular structure ensures dimensional tolerance without microcracks
Thickness accuracy (less than 1.5 thickness is achievable)
Airtightness and pressure
Longevity
Many alloys to choose from with various chemical and mechanical properties
Can produce parts with very complex designs

 

 

Applications of Aluminum Casting Parts

Aluminum alloy has some excellent mechanical advantages. Therefore, you will see them in many applications. For example, they are an integral part of the automotive and construction industries.
Here are some of the top applications of aluminum alloy die casting.

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Construction

You will see aluminum in roof superstructures, window frames, etc. These days large structures such as bridges and commercial buildings also use die-cast aluminum parts in the construction process.

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Automotive

Aluminum alloys are lightweight, which is also an essential feature for modern-day vehicles. Therefore, you would see these alloys in a wide range of applications in the automotive industry. From engine to body parts, they are everywhere.

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Electronics Industry

Over the past two decades, no other industry has risen more than the electronic industry. The innovation of consumer products in these industries has been outstanding. And aluminum has been playing a major role in producing those consumer products.
From smartphones to 5G network housing, die-cast aluminum alloy plays a significant role in this development.

The Benefits of Using Aluminum Die Cast Enclosures

 

Aluminum die casting is lightweight and can endure a high range of operating temperatures. Besides, aluminum has other properties such as high strength, corrosion resistance, heat dissipation, and excellent thermal and electrical conductivity. The creation of lighter parts and components is one of the best advantages of aluminum die casting, which offers more surface finishing options unlike any other types of die cast alloys.

 

Aluminum has good electrical and shielding properties that make it the preferred one for use in electronic components and housings. Aluminum die castings can be utilized as perfect enclosures for a wide range of electrical and electronic applications such as CATV amplifier housings, industrial control units, metering controls, and automotive ECU boxes.

 

Aluminum die casting can act as an effective enclosure for electrical circuitry due to its features like RF shielding and weatherproof. Moreover, die castings can be designed in such a way that it serves many of the key features in circuits such as fins and standoff flat surfaces for heat sink transfer and dissipation.

 

Aluminum's excellent heat dissipating properties makes it ideal for transferring heat from the components of a circuit board within the enclosure to the outside. This will reduce the interior temperature thereby protecting the components from damage due to excessive heat. The other feature of using a die cast enclosure is that it is well suited for use in a wide range of outdoor applications.

 

The Top Considerations During Part Design
 

A few considerations have to be taken into account when designing the part to be cast.
Firstly, the mold must be designed to separate and allow the solidified aluminum part to come out. The line that marks where the two halves of the mold come apart is referred to as a parting line, and you have to consider it in the early stages of die design.

 

Another important consideration is the location of injection points. The die can be designed with several injection points in cases when the molten metal would otherwise solidify before reaching every crevice in the die. This can also help if cavities are included in the design; you can surround them with aluminum and still have the part come off when the mold is separated.

 

You must also consider the thickness of the part's walls. There are usually no guidelines for a minimum wall thickness, thanks to recent technology developments, but having walls with consistent thickness is often preferred.

 

Aluminum die casting processing technology
 

Die cast aluminum parts often require minimal machining, and several options are available for surface finishing. Die casting has a very good surface finish by casting standards but can still have imperfections, like metal seams where the mold halves meet. A rough surface or other imperfections inadequate for the part can be addressed by sanding, sandblasting, or orbital sanding.

 

The cold working process of shot peening is often used on die cast aluminum to improve fatigue resistance. Alternatively, a protective or decorative coating can be applied to the finished part, such as a powder coat. Other types of modifications can also be applied to the parts after casting, such as drill tapping.

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Knurled Aluminum Knob

The Most Common Aluminum Die Casting Alloys

 

Die Casting Aluminum Components

A few of the most commonly used aluminum alloys for die casting are A380, 383, B390, A413, A360, and CC401. The primary consideration when choosing an appropriate alloy is your intended application.

 

For example, A360 offers excellent corrosion resistance, pressure tightness, and very good fluidity when molten. B390 offers outstanding wear resistance and high hardness while having the lowest ductility of all cast alloys, which is why it is used for applications such as automotive engine blocks. Alloy A380 is the perfect jack-of-all-trades, offering a good combination of casting and product properties, and is the most commonly specified alloy for casting a wide variety of products.

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Certifications

As a professional plastic injection molding and die-casting manufacturer, MINDWELL exports all the injection molded parts and die-casting parts to countries all over the world. Our factory is ISO 9001:2015 certified and has perfect quality control procedures. We also have raw material certification, CE certification, SGS certification, etc.

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Our Factory

 

Our company is an industry & trading company that covers research and development, production, processing, and sales. Our company has lots of excellent workers who design and make a mold to reach our customer's requirements.

 

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FAQ
 

 

Q: Why is aluminium good for casting?

A: Aluminum alloys have a wide range of strength characteristics with tensile strengths ranging from 70 to 700 MPa. At low temperatures, the strength of aluminum increases, while at high temperatures, it decreases. Aluminum can also be easily machined, and the power required is low due to the lower density.

Q: What is the main advantage of using die casting process?

A: Die casting is characterized by high dimensional accuracy and allows for the mass production of thin-walled products with complex shapes. Die casting also has the advantage of producing smooth casting surfaces requiring less machining after molding.

Q: Is Die Cast aluminum better than aluminum?

A: Die casting creates parts and components that are more durable, aesthetically appealing, and dimensionally stable than other methods. It can be done with thinner walls than other casting methods, and the produced parts are much stronger than other methods.

Q: Is aluminum casting strong?

A: Cast aluminum is very strong. Since it can withstand weight and stress, it's often used in construction and industrial machinery. To further increase strength and remove flexibility properties, aluminum castings can be heat treated. T5 and T6 are common heat treatments.

Q: Which is better cast aluminum or steel?

A: Compared to steel castings, aluminium castings have a low heat strength. Aluminium melts at low temperatures, so it can be used for both creating products and for modifying them. However, if the product will be used in a high-temperature environment, steel casting is recommended.

Q: What are the advantages of die casting process and its limitations?

A: Die casting requires less machining and other finishing operations. Die casting has better dimensional tolerances and greater production efficiency. Porosity is common to both die casting and sand casting. However, there are precautions to prevent it in die casting, but it is almost impossible in sand casting.

Q: Is die cast aluminum good for health?

A: Despite some ridiculous reports, it is safe to use for cooking and poses no health risks at all. If you're looking for pots and pans made from this material, the good news is they're everywhere.

Q: Is aluminum die casting expensive?

A: The main reason why aluminum die casting is expensive is labor cost. Aluminum die casting is one of the most efficient methods of transforming raw material into a fine, finished part shape. This allows the designer to add features to the part that may not be necessary and make the process expensive or impractical.

Q: Is die cast aluminum brittle?

A: But cast aluminum is less brittle than cast iron. Cast iron parts can have fractures over time, unlike casting aluminum. And cast iron components get rusty but aluminum components don't.

Q: How thick can you cast aluminum?

A: The typical wall thicknesses for aluminum die casting design can range from 0.787 in. (2.0mm) to 0.1737 in. (3.5mm). It also depends on the part's size and structure.

Q: How do you strengthen aluminum casting?

A: All aluminum alloys can be strengthened by cold working. During the cold working, the strength of a metal increases due to the increase in the number of dislocations in the metal compared to its pre-cold-worked condition.

Q: How do you make cast aluminum stronger?

A: Work hardening or “strain hardening” can also be used to strengthen aluminum. This process involves shaping the metal at a temperature that is below its recrystallization temperature, which is normally room temperature. The actual process can involve forging, bending, drawing, or rolling the aluminum.

Q: Does cast aluminum crack easily?

A: Another common cause of cracks in aluminum castings is thermal stress, which occurs when the metal cools too quickly or unevenly. This can happen if the mold temperature is too low, the metal is poured too quickly, or the casting is not properly insulated.

Q: Can you leave cast aluminum outside?

A: Weather-Resistant: This goes for rain, snow and the sun's ultraviolet rays as well. Cast aluminum holds up well as outdoor furniture in all kinds of conditions.

Q: Does cast aluminum get hot in the sun?

A: For another, aluminum is a bit hotter than wood or other materials. It doesn't absorb as much heat as wrought iron, but it can still be uncomfortable seating without cushions in the heat of summer. All in all, cast aluminum patio furniture is a great investment due to its longevity, durability and good looks.

Q: Why is die casting so expensive?

A: Tooling cost is usually one of the biggest concerns when it comes to precision die casting. Because this process employs molten metals at very high temperatures and pressure, die cast tooling is created from special steels that can withstand these conditions.

Q: Is die casting cheaper than machining?

A: CNC machining tends to be more expensive than die casting, but this depends on the type of parts and level of production. Often, CNC machining is used to create the die, and/or to add more intricate features after a part has been die cast.

Q: Why is die casting expensive?

A: Moreover, die-casts are used for large production, which would require a machine with a large clamping force. Also, for high flow, materials would further need a tonnage machine. Therefore extra costs are incurred in the production process.

Q: Is die casting permanent?

A: Die casting is a permanent mold casting process in which molten metal is injected into a mold cavity under high pressure. The pressure is maintained during solidification, after which the mold is opened and casting is removed.

Q: What is the most suitable material for die casting?

A: Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

We're well-known as one of the leading aluminum die casting manufacturers and suppliers in China. With 15 years' experience, our factory offers high quality aluminum die casting made in China with competitive price. Welcome to contact us for custom service.

Precision Machining Aluminum Parts, Die Casting Round Parts, high pressure die casting aluminum alloys