Aluminum die casting is a manufacturing process. The aluminum material is heated and liquefied, and the molten aluminum is then poured into the mold. Usually, we use sand molds or metal molds. Sand molds are mainly used for casting aluminum parts with complex structures. Metal molds are more suitable for die cast aluminum because metal molds are more stable and more efficient. The mold selection of die-casting aluminum can be selected according to the design of the part. Pour liquid aluminum into the mold cavity to obtain parts of various shapes and sizes called die-cast aluminum parts.
1. The die-cast aluminum process includes four main steps
1.1 Mold preparation
After the mold has been designed for the aluminum part to be die-cast, the mold preparation step involves cleaning the mold and applying lubricant to prevent sticking.
1.2 Melting and casting
Normally, there will be an electric melting furnace to melt aluminum, aluminum alloy, and other materials, and pour the aluminum that has been melted in the furnace into the mold through die-casting equipment, and inject it into the mold under high pressure.
1.3 Ejection
After the aluminum solidifies, the mold is opened and the component is ejected.
1.4 Finishing
The finishing step involves removing any excess material and applying any necessary finishing, such as surface treatments as polishing or painting the die-cast aluminum part.
2. Advantages of die-cast aluminum
One of the main advantages of die-cast aluminum is its strength-to-weight ratio. Aluminum is a lightweight material, but it is also very strong and durable, making it ideal for components that need to be both lightweight and strong. Additionally, die casting enables high precision and accuracy, allowing the manufacture of components with tight tolerances and complex shapes.
3. Process characteristics of aluminum die-casting mold
The aluminum die casting mold is quickly filled in the row cavity of the die-casting mold under certain conditions under high pressure and cooled rapidly under certain pressure. The die-casting process is the process of organically combining and using the three die-casting production elements of the die-casting alloy die-casting mold machine.
Aluminum die-casting molds have the advantages of high precision, low surface roughness, and high material utilization. Not only can metal parts with complex shapes, clear outlines, thin walls, and deep cavities be manufactured, but also parts of other materials can be directly embedded in the die-casting parts. to help save valuable material and machining. Therefore, die casting has a dense structure, high strength and hardness, and high productivity. However, die castings often have pores and oxide inclusions, which are not suitable for small-batch production. The size of die castings is limited, and the types of die-casting alloys are limited.
4. Application of aluminum die casting process
Die cast aluminum is used in a wide range of industries including automotive, aerospace, electronics, and consumer goods.
4.1 In the automotive industry
die-cast aluminum is used to make engine blocks, gearboxes, and other components that require high strength and durability.
4.2 In the aerospace industry
it is used to manufacture components for aircraft engines and other critical applications.
4.3 In the electronics industry
it is used to make components for computers, smartphones, and other electronic devices.
4.4 There are still many industries
that can use aluminum die-casting technology, such as medical equipment, ships, and home furnishing.
5. The difference between aluminum die castings
Several common types of aluminum die castings are:
1) Mold components for industrial pure aluminum molding;
2) Dies for high-purity aluminum alloy compression molding;
3) Standard copper and copper alloy die components;
4) Wear-resistant components are made of specific metals based on iron or cobalt. How to Choose the Best Material When selecting a material, consider first if its chemical composition satisfies the requirements, and then whether the surface treatment is qualified.
In the end, we can conclude that aluminum die casting is a versatile and reliable manufacturing process that offers many advantages over other manufacturing methods. Its strength-to-weight ratio, high precision, and ability to create complex shapes make it a popular choice for a wide range of applications and is one of the most important manufacturing processes.