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CHINA ONE STOP PRECISION ALUMINUM DIE CASTING MANUFACTURER

  • ISO 9001 & ISO 13485 & IATF 16949 certified company
  • 1-Stop Aluminum Die Casting Service In China
  • 10+ years experience, 4  facilities & 182 professionals
  • Fast production assures you always on-time delivery
  • Welcome High-Mix, Low volume Projects

We customize all orders to suit your budget and business plan so that you can run your production lines smoothly!

ALUMINUM DIE CASTING CAPABILITY

Sunrise Metal offers a wide range of services other than just die casting. The goal of our company is to provide you a one-stop solution for your project. Starting from rapid prototyping to quality surface finishing, Sunrise Metal helps you get the final product with ease and here in one place

Rapid Prototyping

Sunrise Metal is committed to making real-life products out of your dreams. When it comes to rapid prototyping, we can deliver you the desired products in ½ the time compared to other manufacturers with the highest quality assurance.

Our high mix and low to medium volume prototyping workshop allow you to have the best output within a very short amount of time. Sunrise Metal is one of the leading companies in this sector when it comes to R&D. Along with advanced technologies, professional and experienced engineers, we ensure that our clients are getting the best service for their projects.

Die Casting Tooling

Our state-of-the-art in-house tooling shop allows us to provide complete solutions from tooling design, manufacturing, modification, and maintenance to tooling end management.

Sunrise Metal has years of experience in die casting tooling, which reflects on your final product, and the quality of the mold. Our rapid tooling service only takes 2-4 weeks or less, depending on your volume and requirements.

The advanced equipment and machines make us capable of providing world-class service in making any molds or tools.

Die Casting Aluminum Production

With 280T to 1600T machines and two specialized die casting facilities, we have the highest capabilities to deliver the best quality parts for our customers. The broad scope of materials, machines, and years of experience help us make the exact product that meets your demand well.

Sunrise Metal has been serving customers worldwide with premium quality parts for more than 10 years. Being one of the leading die casting manufacturers globally, we take 100% responsibility for our products’ quality.

CNC Machining

To meet our customers’ demand worldwide, Sunrise Metal equipped 23 sets of CNC Machining Center and 4 CNC Lathe in our die casting shop. This enables us to provide not only the machining for die casting parts but also provide machining from solid, extrusion, gravity casting, forging, etc. The high-tech engineering and expert workforce allow us to provide a precise and highly accurate CNC machining service according to your requirements.

Surface Finishing

To give our customers a one-stop solution,  we’re capable of serving you with various high-quality surface finishing options that go with your final products. All our surface treatments are ROHS & REACH compliant.

We’re providing:

Shot BlastingPowder Coating Liquid PaintingElectroless Nickel

AnodizationSilk ScreeningPad ScreeningChromate-Surtec 650

Whether your projects are in the proof-of-concept design or ready for production, Sunrise Metal wants to support them.

Quote Now to Start Your Aluminum Die Casting Projects.

 

RICH MANUFACTURING EXPERIENCE ON 2500+ ALUMINUM DIE CASTING PARTS

The precision aluminum die casting products we manufactured mainly involve in Marine, Medical, Automotive, Aerospace, Telecommunication industry. Our team will witness the entire processes of each product from DFM to mass production. Hope we will have a chance to help you.
  • Aluminum-Die-cast-Coffee-machine-components
    Die cast Coffee Component
    Coffee Machine Component For Israel Client with Powder Coating
  • Aluminum-Die-casting-Marine-Powder-coated
    Die Casted Marine Part
    Marine Radar Component For UK Client with Powder Coating
  • Aluminum-Die-casting-Coated-Plate
    Die Casted Coated Plate
    Navigation Display Component For UK Client with Powder Coating
  • Aluminum-Die-cast-engine-pipe
    Die casted Engine Pipe
    Automotive Casting Part For Germany Client with Sand Blasting
  • Aluminum-Die-Casting-power-cover
    Die Casted Power Cover
    Power Tool Component For American Client with Powder Coating
  • Aluminum-Die-casting-braket
    Die Casted Bracket
    Dental 3D Scanner Component For Danish Client with Surtec 650
  • Aluminum-Diecast-frame
    Die Casted Frame
    Medical Ultrasound Component For American Client with Powder Coating
  • Aluminum-Die-casting-Telecom-part-Aluminum-Die-Casting-Manufacture
    Die Casted Display Frame
    Telecom Enclosure Component For Canadian Client with Powder Coating

HOW SUNRISE METAL SUCCEED YOUR ALUMINUM DIE CASTING PROJECTS

Strict Quality Control

We have experienced quality engineers and deploy advanced quality equipment. We take strict quality control for every production process.  All we do is to assure the best quality of the products and services we provide to you.

Strong Engineering Support

With an average of 10 years’ experienced engineering team, we provide you DFM, engineering support during the whole project life.

One-Stop Solution

We provide you one-stop service integrating Rapid Prototyping, Tooling, Aluminum Die Casting,  CNC Machining & Surface Finishings.

  • Strict-Quality-Control-Advantage
  • Mold-Design-Review-for-aluminum-die-casting-projects-Advantage
  • Second-Surface-Finishing-for-aluminum-die-casting-parts

ADVANCED ALUMINUM DIE CASTING MANUFACTURING EQUIPMENT AT SUNRISE

With state-of-the-art production equipment, we can produce custom aluminum die casting parts for you. Our die casting tooling equipment, aluminum die casting machines, CNC machining centers, different surface finishing prodcution lines are showed below.
  • Tooling Equipment
    High precision tooling equipment in-house
  • Aluminum Die Casting Machines
    Die casting machines ranging from 160T to 1600T
  • CNC Machining Centers
    High precision 3 & 4 & 5 & 7 axis CNC machining equipment
  • Chromating Production Lines
    Automated Cr6+ free chromating cleaning
  • Automated Powder Coating
    Capable of various colors powder coating
  • Electro Plating Lines
    ROHS & Reach compliance plating production

YOU CAN EXPECT STRICT QUALITY CONTROL ON YOUR ALUMINUM DIE CASTING PARTS

As an ISO13485 & IATF16949 & ISO9001 certified company, our well trained quality staff control your every aluminum die casting products. With full set high precision measuring equipment, we always guarantee the quality for you in the whole project life.
  • Tooling Quality Control
    Mold in-process dimension varification
  • Spectrum Meter Instrument
    Material composition checking
  • On-site Produciton Control
    Die casting process patrol checking each 2H
  • X-ray Detector
    Die casting porosity & inside defects checking
  • On-site Production Inpection
    Recording sand blasting production checking result
  • On-site Leakage Inspection
    Pressure test to ensure parts leakage free
  • Carl Zeiss CMM Equipment
    High precision instrument with automatic scanning
  • Projector Measuring Equipment
    2D demension inspection for parts
  • Cleaniness Test Equipment
    Particle control on die casted parts surface
  • Product Diemension Control
    Full dimension measuring for die casted parts

GLOBAL CUSTOMERS VISIT

As a leading China aluminum die casting company, Sunrise Metal provides aluminum die casting service worldwide. Many global clients visit Sunrise Metal to check our capability and capacity. Through on-site factory tour, they trust us and award us with more business. To better know our customers’ business needs and products, we also regularly visit our global customers.

Warmly welcome you to visit us.

GLOBAL-BASED CUSTOMERS

Our High-quality products and always on-time delivery win us a great reputation from customers globally. Most of our customers are hidden champions in their fields. We also hope to be your partner and success your business with our innovation service. Here below are some references for you.

Sunrise is an ISO 9001 & ISO 13485 & IATF 16949 certified manufacturer. With these quality system certifications, we can offer you better service in aluminum die casting projects.

IATF 16949

Below equipment allows us to offer a 1-stop solution for you from die casting mold design, mold making, regular mold repair, and mold maintenance.

Die Casting Tooling WorkShop (Nantong)
Machining Type Brand Model Stroke Unit
Grinder TATUNG-OKUMA KGS-615AHD From 380mm to 1600mm 4
Drilling ShenYang Machine Z3050*16/1 1600mm 1
Sawer Juli MJ034W NA 1
Lather Shanghai 2nd Machine C6250A 1000mm 1
EDM EDM Korea YIHAWJET Taiwan NA From 438mm to 1100mm 8
CNC Local Brand SONYU-SL850 From 850mm to 3015mm 5
Wire Cutting Local Brand DK7763 800*630mm/1000*800mm 2
Milling Machine Local Brand QJM-S2 NA 4
High-speed Cutting Machine Local Brand 906148 750mm 1
Deep Hole Drilling Local Brand DHD-1513 1513mm 1
Die Spotting Machine Nice Dongguan NC150-1511 1400mm 1
EDM/wire cutting Combined Machine Local Brand DK7755 550*630mm 1
EDM for very small hole Local Brand DD703 300*400mm 1
3D Laser Scanner Sikan Hangzhou HSCAN771 NA 1

Our in-house facilities own 11 sets of aluminum die casting machines. To better provide high-quality die casting parts for you, we will continue to invest in the related equipment.

 Kunshan Die Casting WorkShop
Die Casting Machine Type Brand Ton Unit
Aluminum Die Casting Machines LK 280T 1
LK 400T 1
LK 500T 1
LK 800T 1
Nantong Die Casting WorkShop
Die Casting Machine Type Brand Ton Unit
Aluminum Die Casting Machines LK 280T 1
LK 300T 1
Yizumi 400T 1
Buhler 500T 1
LK 630T 1
Toshiba 800T 1
LK 1600T 1

Our laboratory is equipped with comprehensive measuring equipment to help make sure we can provide you with high-quality and stable aluminum die casting parts.

CNC Machining Production Equipment
No. Equipment Q’ ty
1 CNC Lathe 4
2 CNC Machining Center 17
3 Fanuc CNC Machining Center 2
4 Hass CNC Machining Center 2
6 Grinding machine 4
7 Saw Machine 1
8 Drilling Machine 2

ALUMINUM DIE CASTING HANDBOOK

Aluminum Die casting is a manufacturing process in which the molten aluminum alloy is injected under high pressure into a steel mold.  It’s one of the most popular manufacturing processes for the volume production.

In this handbook, we have highlighted all the essential information. You can get a proper understanding of any chapter you’re interested in by clicking the jump links in blue.

CHAP1 Introduction CHAP7 Aluminum Die Casting Design
CHAP2 Aluminum Die Casting Process CHAP8 Aluminum Die Casting Defects
CHAP3 Aluminum Alloy Materials CHAP9 Aluminum Die Casting Products
CHAP4 Aluminum Die Casting Equipment CHAP10 Aluminum Die Casting Services
CHAP5 Advantages & Limitations CHAP11 Future Development
CHAP6 Applications CHAP12 Conclusion

ALUMINUM DIE CASTING HANBOOK

Chapter 1 Introduction

Die casting is a manufacturing process to produce parts from various metal alloys with high precision. The process involves the injection of molten metal under high pressure into a steel mold. When we use aluminum alloys as raw material, we call this process aluminum die casting. It is one of the most popular manufacturing processes for large volume production of metal parts.

In this Aluminum Die Casting Handbook, we have highlighted all the essential information about the aluminum die casting process. If you are new to aluminum die casting, we believe this handbook is all you need to get started.

History

Figure-2-History-of-Aluminum-Die-Casting

Despite the massive popularity nowadays, it hasn’t been that long since aluminum die casting started being used in the industries. Compared to other metalworking methods that have been used in human civilization for centuries such as forging and investment casting, aluminum die casting is rather new to us.

The first die casting equipment was invented in 1838. Though, it was primarily used by the printing industry at that time for making movable type. However, the first die casting-based patent was approved in 1849. But the machines were still at an early stage and were hand-operated.

Over time engineers have developed a better version of the machine and it was slowly being adopted in other industries as well. In the late 1950s and 1960s, General Motors developed a process called Acurad to cast low-iron aluminum alloys. This process was closest to our modern-day aluminum die casting process. Since then, the process was continuously upgraded to increase its efficiency and capacity.

Impact on the Industry

The aluminum die casting process had completely revolutionized the manufacturing industry. Initially, lead and tin were mainly used in the die casting process. But, by the 1930s, most low melting point metal alloys such as Aluminum, Zinc, Magnesium could be successfully die casting.

The discovery of Aluminum is rather recent. Even a few centuries ago, aluminum used to be a very rare metal. It was even costlier than gold at some point. However, by the 20th century, proper Aluminum refining processes were put into practice, which made mass production of Aluminum possible.

It soon became one of the cheapest yet most efficient metals in terms of strength-to-weight ratio. Therefore, aluminum die casting, in particular, gained massive popularity among manufacturers. It has replaced many commonly used alloys and manufacturing techniques of that time. Today, a significant market share of the global manufacturing industry belongs to aluminum die casting alone.

Chapter 2: Aluminum Die Casting Process

The complete process of aluminum die casting consists of some fundamental steps. But, before you can get started with the process, you have to prepare a set of molds called die based on the product to be manufactured. This process is called die tooling. You only have to prepare the molds once, and you can use them to cast thousands of parts.

Basic Steps of Aluminum Die Casting

We have explained the basic steps involved in a typical aluminum die casting process below.

Basic Steps of Aluminum Die CastingMelting

The first step is to melt the aluminum alloy inside a suitable furnace. Due to the aluminum alloy’s high melting point, the furnace is located outside the machine. The typical melting temperature of alloys is about  660oC. However, for die casting, alloys must be heated to a higher temperature than the melting temperature to be able to pour it properly. For aluminum alloys, the pouring temperature range is 700oC to 750oC.

But caution should be taken not to raise the temperature higher than that, as it would adversely affect the quality of the casting. Also, note that a sufficient quantity of aluminum alloy is melted inside the furnace at once. For the rest of the session, we only carry the molten aluminum from the furnace and pour it into the injection unit.

Die Preparation

Before each casting cycle, the die halves are cleaned to remove any residue that may be left from the previous injection. Then, lubricant is sprayed onto the die halves to enable easier removal of the next casting. While lubricant is essential, it may not be necessary to spray it after every casting cycle.

Usually, lubricating the dies every 2 or 3 cycles is enough, though it can vary depending on some factors such as casting size and material. Once done, the dies are clamped together with a specified amount of clamping force to form a cavity. The clamping force is a key determinant of a die casting machine’s capacity. Bigger castings require machines with higher clamping force.

Pouring

Pouring of the metal sounds like a simple thing to do. However, it is an important step for aluminum die casting. The melting furnace is located outside the die casting machine. So, we need to transfer the molten aluminum to the shot chamber with the help of a ladle.

The pouring process is usually done manually by workers. However, there are robot-operated die casting machines as well. Automation of the process saves time and also eliminates the risk of hazards to workers.

Injection

Then molten aluminum is poured into the shot chamber, and injected into the die cavity using a plunger. The plunger gradually forces the molten aluminum inside to fills up the cavity. The plunger is powered by a hydraulic cylinder, and injection speed & force is specified based on the casting requirements.

Solidification

When the hot molten aluminum has taken shape inside the cavity, it is left inside the die cavity for a brief moment to let it cool down and solidify. During this time the plunger retains the applied pressure. When solidification is complete, the plunger retracts backward.

Ejection

Finally, the dies are opened to retrieve the casting. Usually, the moving die is equipped with an ejection mechanism that automatically pushes out the completed casting from the die using ejector pins. Or, it may also be manually removed from the die.

Different Aluminum Die Casting Processes

The aforementioned steps are the most widely used process for aluminum die casting. However, there are various methods for aluminum die casting. The processes are differentiated from each other based on various criteria. The most common processes are,

  • Pressure Die Casting
  • Vacuum Die Casting
  • Gravity Die Casting
  • Squeeze Die Casting
  • Semi-Solid Die Casting

We have discussed each of the processes in brief to give you some basic ideas.

Pressure Die Casting

High-Pressure vs Low Pressure Aluminum Die Casting

Pressure die casting is one of the most common forms of aluminum die casting that is widely used in the industry. In this process, external pressure is applied to cast the parts. Based on the extent of pressure applied during the process, aluminum pressure die casting can be further classified into the following two categories:

  1. High-Pressure Aluminum Die Casting
  2. Low-Pressure Aluminum Die Casting

The basic steps of aluminum die casting discussed previously mainly resemble the high-pressure die casting process. It is by far the most popular aluminum die casting methods that are used by more than 70% of the manufacturers. It is a rapid process that and mainly suitable for the mass production of parts.

On the contrary, low-pressure aluminum die casting is preferable when we are dealing with larger parts and want to reduce the porosity in casting. However, the process is rather slow, and it is difficult to cast intricate parts with thin walls.

To learn more, you can read our detailed blog on Pressure Die Casting or another blog that shows the comparison of High Pressure vs Aluminum Die Casting.

Vacuum Die Casting

Aluminum Vacuum Die Casting Production Process

The vacuum die casting process aims to reduce or nearly eliminate pores in aluminum die casting parts. The machine setup and process are almost the same as that of a typical high pressure aluminum die casting process. Therefore, it can be thought of as an upgrade to the conventional process.

Here, an additional vacuum unit is attached to the die cavity to remove the entrapped air prior to every casting cycle. So, it is also known as vacuum-assisted die casting.

Read our dedicated blog on Vacuum Die Casting or our FAQ Guide if you wish to learn more about this process.

 

Gravity Die Casting

The gravity die casting process is one of the most simple and inexpensive aluminum die casting processes. Unlike the other die casting methods, gravity die casting does not require any external pressure. Molten aluminum is gradually poured into the mold cavity to fill it up.

The finished product has low porosity and a good surface finish. However, this process is considerably slow as it takes place under the gravity force. Therefore, it is mainly used for low volume casting requirements or prototyping of parts.

Here’s a link to our separate blog on Gravity Die Casting.Aluminum Gravity Die Casting Process

Squeeze Die Casting

Squeeze die casting is an upgrade to the traditional gravity die casting process. The initial steps are the same as that of gravity die casting. After filling the cavity, slowly pressure is applied to the casting to make it more compact and pore-free. This process is more costly but ensures higher quality for the casting.

Check out our Squeeze Die Casting blog to learn about the complete process. It will also help you understand whether this process is suitable for your project.

Aluminum Squeeze Die Casting Process

Semi-Solid Die Casting

As the name implies, semi-solid die casting deals with aluminum alloys in a semi-solid condition instead of fully melting them. The main goal is to retain the mechanical properties of a forged part, yet do it more conveniently. There are currently three methods to work with semi-solid alloys,

  1. Rheocasting
  2. Thixocasting
  3. ThixomoldingAluminum Semi-Solid Die Casting Process

Aluminum semi-solid die casting is done using the rheocasting or thixocasting process. We have a separate blog discussing the Rheocasting and Thixocasting Differences.

You can check out our Semi-Solid Die Casting blog as well. It will help you understand the difference between the conventional and semi-solid die casting processes.

Chapter 3: Aluminum Alloy Materials

Aluminum die casting is done with some specific type of aluminum alloy. This section will discuss the basic characteristics of aluminum alloys in general, and also the properties of common aluminum alloys used for die casting.

Figure-10-–-Chapter-3-Materials

Characteristics of Aluminum Alloys

Aluminum alloys have some unique properties that make them an excellent choice as die casting material. Below we have discussed the main characteristics of aluminum die casting alloys.

  • Lightweight; has a superior strength-to-weight ratio
  • Excellent corrosion resistance
  • Components can operate under high temperatures
  • Excellent Tensile strength and hardness
  • Excellent thermal and electrical conductivity
  • Can be fully recycled
  • Parts have a good surface finish
  • Great EMI and RFI shielding Properties

Types of Alloys

There are numerous types of aluminum alloys in existence. But, only a selected few of them are used die casting, including,

  • A304 (K-Alloy)
  • A360
  • A380
  • A383 (ADC12)
  • A413
  • B390

Each of these alloys has slightly different characteristics compared to the properties of raw aluminum. We have briefly discussed each of the alloys used for die casting.

A304 (K-Alloy)

It is a patented aluminum alloy that was specially designed to protect parts from hast conditions. The A304, also popularly known as K-alloy has superior corrosion resistance along with better thermal conductivity which offers improved cooling of parts.

Moreover, K-alloy diecast parts have excellent surface finishing which eliminates the need for basic surface treatment operations like painting or anodizing. You can read our detailed blog on K-alloy Properties And Advantages and Industries using K-alloy to learn more.

A360

A360 aluminum alloy ensures better pressure tightness and fluidity for diecast parts. Due to having a higher silicon content, the A360 exhibits better corrosion resistance even in a higher range of temperatures.

A380

A380 is one of the most popular alloys in the aluminum die casting industry. It can be thought of as an all-rounder alloy with a great combination of mechanical, thermal, and casting properties. It is convenient to work with and has a perfect balance of strength and performance which should be ideal for most applications.

Read our dedicated blog on Aluminum A380 Alloy to learn more.

A383 (ADC12)

A383, also known as ADC12. It is often used as an alternative to the A380 alloy as their properties are quite similar. But it has better fluidity, therefore is easier to work with. It provides good dimensional stability and can cast parts with intricate details.

A413

The A413 has a good balance of physical and mechanical properties. It has good pressure tightness and is not prone to hot cracking. Therefore, it is an ideal choice for die casting parts like hydraulic cylinders. Moreover, its fluidity allows the casting of complex shapes as well.

B390

B390 aluminum alloy is the right choice if you are need parts with more hardness and wear resistance. It is commonly used in the automotive industry for casting parts such as pistons for the combustion engine and cylinder bodies for brakes and compressors.

Composition of Alloys

Different aluminum alloys have different compositions of alloying elements in them. A comparative chart of the ratio of alloying elements present in each type of aluminum alloy is shown below:

Table 1 – Composition of Aluminum Alloys

Composition of Aluminum Alloys
A304 A360 A380 A383 A413 B390
Aluminum Primary Primary Primary Primary Primary Primary
Magnesium 0.35 – 0.50 0.35 – 0.50 0.1 0.1 2.0 0.45-0.65
Iron (max) 0.8 – 1.0 0.8 – 1.0 1.3 1.3 2.0 1.3
Zinc 0.20 0.20 3.0 3.0 0.5 1.5
Silicon 9.0 – 11.5 9.0 – 11.5 7.5-9.5 9.5-11.5 11.0-13.0 16.0-18.0
Copper 0.05 – 0.08 0.05 – 0.08 3.0-4.0 2.0-3.0 1.0 4.0-5.0
Tin (max) 0.03 0.03 0.35 0.15 0.15
Nickel (max) 0.03 0.03 0.5 0.3 0.5 0.1
Manganese 0.50 – 0.60 0.50 – 0.60 0.5 0.5 0.35 0.5
Others 0.5 0.5 0.25 0.2

*Aluminum is the primary/base metal here. The total percentage varies depending on the percent of the alloying elements.

Properties of Alloys

The difference in alloying composition of the alloys affects their mechanical and physical properties. Below we have shown the comparison charts of the mechanical and physical properties.

Table 2Mechanical Properties of Aluminum Alloys

Mechanical Properties of Aluminum Alloys
A304 A360 A380 A383 A413 B390
Hardness 80 75 75 80 80 120
Tensile Strength 295 317 310 324 290 317
Yield Strength 172 170 150 160 130 250
Elongation 5 3.5 3.5 3.5 3.5 1
Shear Capacity 180 190 170
Impact Strength 4 4

Table 3 – Physical Properties of Aluminum Alloys

Physical Properties of Aluminum Alloys
A304 A360 A380 A383 A413 B390
Density 2.63 2.63 2.71 2.74 2.66 2.71
Melting Point (Average ±50) 680 577 566 549 578 580
Thermal Expansion Coefficient 21 21.8 21.1 21.6 18
Thermal Conductivity 113 113 96 96 121 134
Electrical Conductivity 32 29 23 23 31 27

Aluminum vs Other Die Casting Metals

There are various die casting metals in the market including aluminum. However, they are primarily non-ferrous metals and their alloys. Apart from Aluminum, some other non-ferrous metals used for die casting includes,

  • Zinc
  • Magnesium
  • Copper
  • Titanium
  • Tin
  • Lead

Aluminum die casting has the largest market share compared to other metals. However, there are certain applications when other metals could offer better value. Zinc is the second most die casting metal after aluminum.

Magnesium and Titanium are mainly popular in industries with a focus on lightweight metals. But Tin and Lead are rarely used nowadays due to their hazardous impacts.

Below we have shown a comparison among various die casting metals.

Table 4 – Comparison Chart of Aluminum vs Other Die Casting Metal

Comparison Chart of Die Casting Metals
Aluminum Zinc Magnesium Copper Titanium Lead Tin
Melting Point, oC 660.3 419.5 650 1085 1668 327.5 231.9
Specific Gravity 2.7 7.0 1.74 8.95 4.51 11.34 7.265
Ultimate Tensile Strength, MPa 90 – 586(A304L) 90 246 200 520 12 200
Yield Strength, MPa 35 – 241(A304L) 75 148 70 450 5.5 9-14
Young’s Modulus, GPa 70 108 45 130 116 16 50
Hardness (Brinell), MPa 184 480 -520 44 520 1028 37.5 -41.8 292 -441
Density Relative to Aluminum 2.64 0.64 3.31 1.67 4.20 2.70

*The values can vary for different alloys of the same metal.

Now, each of the aforementioned metals has different types of alloys as well. For example, Alloys of Zinc are Zamak and ZA alloys. However, some metal alloys don’t belong to a specific metal group as they consist of a significant percentage of two or more alloying elements. Example of such alloys includes,

  • Brass, Alloy of Copper and Zinc
  • Bronze, Alloy of Copper and Tin

However, Brass and Bronze is not your every diecast metal. They are difficult to cast as they have a high melting temperature due to the high percentage of copper. So, the manufacturing process is more complex and expensive. Therefore, their scope of application is limited to some specific industries.

Chapter 4: Aluminum Die Casting Equipment

Figure-16-–-Chapter-4-die-casting-Equipment.

Aluminum die casting is a sophisticated metalworking process involving the use of various types of equipment. A typical casting process requires,

  • CNC machine for tooling of dies
  • Furnace for melting the aluminum alloy ingots/billets
  • Cold chamber die casting machine for casting the aluminum
  • Additional equipment for post-processing and surface treatment of castings

However, we will only discuss the cold chamber machine that casts the aluminum here. You can check out our other blogs if you wish to learn about various other equipment involved in the complete process.

Components of Die Casting Machine

Components of Aluminum Die Casting Machine

A typical cold chamber die casting machine can be divided into three units or compartments based on the processes taking place.

  • Injection Unit
  • Casting Unit
  • Clamping Unit

Now, each of these units is comprised of several smaller components. The components of a conventional die casting machine and their function are briefly discussed in the following section.

Injection Unit

The main components of the injection unit of a cold chamber aluminum die casting machine are the shot chamber, plunger, hydraulic cylinder, shot sleeve, etc.

Shot Chamber: Molten aluminum transported from the furnace with a ladle is poured into the shot chamber.

Plunger: The plunger is a rod with a flat cylindrical head that pushes the molten aluminum through the shot sleeve into the die cavity. It is made up of higher quality material to reduce wear.

Hydraulic Cylinder: This is what powers the plunger. It regulates the pressure and speed at which the plunger pushes the material. The injection pressure applied can vary from 2000 psi to 20000 psi. The injection pressure is usually decided based on the volume of casting.

Shot Sleeve: It is the elongated section connecting the die cavity with the shot chamber.

Casting Unit

The casting unit is where the molten aluminum alloy takes shape of the desired product. All the necessary components are within two die halves, which include the Moving Die, Fixed Die, Core insert, Ejector Plate, Ejector Pins, etc.

Fixed Die: The fixed/Cover Die remains stationary during the casting process, therefore it is also known as the stationary die. It holds one part of die inserts.

Moving Die: It is also known as the ejector die. This part houses the ejection mechanism of the machine. During a casting process, only this die half moves perpendicular to the parting line.

Die Inserts: Some machines have a set of removable components called the core insert and cavity insert. Together they form a cavity and give the desired shape to the material. The die inserts are made by CNC machining and can be mounted into the main holding dies.

Ejector: The ejector comprises the ejector plate, pins, retaining plate, and a box that holds them together. The whole setup is mounted into the movable die. The ejector plate holds together a set of ejector pins. The ejector plate pushes the ejector pins forward to eject the casting out of the die.

Clamping Unit

The clamping unit contains all components required to power the die locking and opening mechanism. The capacity of the aluminum die casting machine is measured based on the clamping force. Larger castings require equipment with higher clamping force and vice versa.

The clamping unit has several powerful hydraulic pistons/clamps that move the moving die. The total clamping force dictates the maximum volume material that can be cast successfully. Typically, the clamping force of cold chamber aluminum die casting machines can range from 100 to 2000 Ton.

Types of Dies

Different types of Dies used for Aluminum Die Casting

Depending on the structure of a mold or die, it may be classified into the following types:

  • Single Cavity Die
  • Multi-Cavity Die
  • Unit Die
  • Combination Die

We have discussed each type of die type including their structure and application below.

Single Cavity Die

It is the simplest type of die consisting of only a single cavity. Therefore, it can only cast one type of part at a time. It is best suited when the production volume is low. However, some complex parts require special features in the die such as side cores. Intricate parts need to be cast separately in a single cavity die.

Multi-Cavity Die

The multi-cavity die will be your choice of die, when dealing with a large volume of a single type of part. The initial investment will be higher as more tooling operations will be required for the additional cavities. Moreover, multi-cavity casting will require more powerful die casting machines as well. However, the production cost will be subsided over time for large volume production.

Unit Die

Unit dies are also known die inserts. It is a preferable option when manufacturing high-mix, low-volume parts. It requires significantly less investment, as we only have to change the die insert instead of the whole die. Moreover, unit dies usually have a single cavity only, and they can be changed anytime to cast various types of parts.

Combination Die

A combination die is similar to a multi-cavity die. However, in this case, a single die is used to cast multiple types of parts. A combination die is usually used to cast a set of parts that belongs to a particular product assembly. It can substantially reduce the production time and cost.

Important Parameters and Specifications

Understanding the various specification of aluminum die casting machines are essential for not the manufacturers but also the customer/client as well. It will allow you correctly estimate the requirements for your die casting project and, also to assess the capability of a manufacturer. We have briefly discussed some of the important parameters/specifications below.

Die Locking/Clamping Force:  It is one of the key indicators of the capacity of aluminum die casting equipment. Equipment with higher clamping force can maintain better precision. The clamping force is usually a limiting factor for the maximum volume of casting producible.

Platen Size: It is the size of the die plates. It gives you some idea about the highest size of parts that can be cast using a die casting machine. Both the die height and width should be taken into consideration.

Die Thickness: The maximum and minimum die thickness is a limiting criterion for the thickness of parts.

Injection Force: It is the amount of pressure applied by the plunger during the injection phase of aluminum die casting. The die clamping force and injection force must be balanced properly to avoid defects such as the formation of a flash along the parting line.

Ejector Force: Once a casting cools down or solidifies, it tends to get stuck on the die. Ejector force is the highest amount of force applied by the ejectors to push out a solidified aluminum casting from the die.

Casting Size and Weight: Aluminum die casting machines are designed for the maximum size and weight of the casting. Previously, the maximum casting or shot weight was limited to around 10 kg. However, after the introduction of the Giga Press, the casting of even 80kg parts is now possible.

Popular Machine Brands

The aluminum die casting industry has undergone rapid growth over the last few decades. The involvement of modern technology has allowed manufacturers to significantly cut down on production costs while ensuring higher quality of parts.

Therefore, there is also competition among die casting equipment manufacturers to offer more advanced and efficient machines to us. Some of the top brands that manufacture and assembles die casting machines include,

  • Idra
  • Bühler
  • Toshiba
  • LK Machinery
  • Frech
  • Kurtz Ersa
  • Yizumi, etc.

There are many other good brands as well, we only listed a few renowned ones here. Though, these are among the best in the industry. They have a very strong footprint in the manufacturing industry and are relied upon by industry experts.

Sunrise Metal is a leading aluminum die casting manufacturer in China. We invest in the latest technology die casting equipment from top brands like Toshiba, Bühler, LK Machinery, etc. This is part of the commitment to our clients to ensure the high quality and consistency of our manufactured parts. You can check out our complete lineup of die casting equipment available at our workshop as well.

Chapter 5: Advantages & Limitations

Aluminum die casting is one of the most reliable and efficient techniques for manufacturing metal parts. It has a great number of benefits with few limitations where it can be applied. We have briefly discussed its advantages and limitations in this chapter.

Advantages

Aluminum die casting offers a ton of advantages that makes it an ideal choice for most applications. Below we have discussed the advantages of aluminum die casting taking into consideration several factors.

Strength-to-Weight Ratio

Aluminum is well known for its lightweight compared to other metals. An average Aluminum alloy is almost three times lighter than Iron or Zinc. While Iron and zinc are stronger than aluminum, Aluminum has a superior strength-to-weight ratio. Making it an ideal choice for applications where weight is a big factor.

Versatility

One of the biggest advantages of die casting is its versatility. It allows casting of any shape or design very easily. Aluminum alloys have high fluidity and various other characteristics that make them the perfect material for die casting. So, aluminum die casting is widely used for the production of complex parts.

Surface Finishing

The manufactured parts have good surface finishing which minimizes the need for further post-processing. Also, it is possible to produce parts with both textured or smooth finishing. The castings have an aesthetic look and feel to them that reduces the need for costly surface finishing.

Durability

Aluminum castings have high corrosion and wear resistance compared to most other alloys. Aluminum alloy parts can be safely used in adverse environments. Moreover, there are numerous surface treatment options available as well that can further increase its durability.

Production Efficiency

Aluminum die casting offers superior production efficiency compared to other manufacturing processes. It has become the most popular manufacturing technology worldwide for the mass production of metal parts. And, all of this is achieved while maintaining high quality for the manufactured parts.

Production Cost

Aluminum die casting is considered one of the most cost-efficient production technologies for making metal parts. The lightweight, strength, durability, castability, surface finishing, and production speed all together make it a cost-effective alternative to other manufacturing technologies.

Limitations

Despite being one of the most versatile manufacturing technologies, aluminum die casting does have some limitations regarding its applicability. We have briefly discussed them below.

High Initial Investment

One of the main limitations of aluminum die casting is the relatively higher initial investment involved in the production. The dies required for casting are done by CNC machining, which can be quite costly and time-consuming depending on the complexity of the parts. However, once the mold is ready, it can be used for making thousands of parts, which eventually trims down the cost.

Not Suited for Low Volume

The high initial investment involved in the process also makes it less suitable for low volume production needs. However, some manufacturers utilize unit dies and rapid tooling technologies to make it more affordable for low to medium volume production.

You can check out Sunrise Metal’s aluminum die casting services, as we accept high-mix, low volume die casting projects as well.

Limited Casting Size

The size of parts we can manufacture by aluminum die casting is limited by equipment. The die size along with some other parameters such as the clamping force limits the highest volume of parts that we can cast. However, with the advancement of technology, size limitations are starting to become a thing of the past.

Recently, Tesla has started manufacturing using the Giga Press, the world’s largest die casting machine. It could potentially revolutionize the aluminum die casting industry by overcoming the existing limitations.

Chapter 6: ApplicationsSunrise Metal-Main Industries and Applications of Aluminum Die Casting-

Aluminum die casting is one of the most effective manufacturing processes for the mass production of high-quality metal parts. Therefore, aluminum diecast products have gained immense popularity among various industries lately. The demand for aluminum diecast parts is still on the rise as more industries are switching to aluminum die casting for high-quality parts at a reasonable price.

 

Let’s have a look at the applications of aluminum die casting in some industries.

Automotive Industry

The automotive industry has a huge demand for aluminum die cast parts at present. In order to increase the fuel efficiency of vehicles and make them more affordable, automobile manufacturers have taken a keen interest in aluminum die casting.

Modern aluminum die casting techniques have completely revolutionized the industry. Now, the manufacturing of complex automobile parts is easier than ever. You can read our FAQ guide on Automotive castings for more information.

Construction Industry

Megastructures such as bridges, high-rise buildings, and skyscrapers are becoming more and more common lately. However, the weight of construction material plays a big role in the design of structures, which eventually increases the construction cost.

Therefore, the utilization of aluminum castings in construction projects is increasing day by day. Also, construction equipment are making use of aluminum components as well.

Healthcare Industry

The healthcare industry has a large demand for high precision and complex parts. Aluminum die casting is used to produce housing and internal components for various medical devices such as dialysis equipment, ultrasound systems, hospital beds, monitoring devices, etc. Our Medical Casting blog can help you get more insight regarding the application of Aluminum castings in this industry.

Aerospace Industry

The aerospace industry has a particularly higher demand for parts with a good strength-to-weight ratio. The lighter the parts the better, as it can significantly reduce the fuel consumption. Aluminum and magnesium die casting has become more and more popular in the industry recently.

Energy Industry

The gas and oil sector utilizes various heavy machinery for drilling, piping, flow control operations. There is a good demand for die casting components in these machines. Moreover, the renewable energy sector has a large demand for die casting parts for making solar panels, wind turbines, etc.

Culinary Industry

The culinary industry has a huge demand for aluminum die casting products. They are vastly used for food processing. The lightweight, corrosion resistance, and excellent thermal conductivity of aluminum make it ideal for cookware and kitchen appliances.

Electronics Industry

The electronics industry has been showing increasing interest in aluminum diecast products recently. The lightweight and heat transfer properties have been the most intriguing thing for the electronics industry. The electronics industry utilizes aluminum die casting for making cover/enclosure and heat sink for various electronics products, such as smartphones, appliances, tv, computers, etc.

Marine Industry

The marine industry is utilizing aluminum die casting for making components and equipment for ships, submarines, and various marine installations. Some common applications include casting of pump housings, radar housing, display frame, pedal component, etc. You can check out our blog on Marine Casting to learn about the practical application of aluminum die casting in this industry.

Telecommunications Industry

Aluminum heat sinks, base plates, and enclosures are widely used in various telecommunication devices. The superior electrical & thermal conductivity, EMI & RFI shielding properties, and strength-to-weight ratio make them an ideal choice for telecommunication equipment. Read our Telecom Casting blog to learn about the potential applications of aluminum castings in this industry.

We only discussed some of the major industries utilizing aluminum die casting to give you some idea about the scope of its applications. Small or big, almost every industry has some demand for aluminum diecast components. Many are even inclining towards aluminum die casting to increase production efficiency and reduce production costs.

Chapter 7: Aluminum Die Casting Design

Design for aluminum die casting mainly refers to the model generated for tooling of the dies/molds. But, there are other factors to be considered as well. Because proper design practices are essential to achieve maximum efficiency in die casting. Therefore, the capability of a good aluminum die casting manufacturer also depends on their DFM practices.

In this chapter, we have briefly discussed various aspects of design for aluminum die casting.

Design for Manufacturing (DFM)

Design for Manufacturing (DFM) is the process to optimize a part design so that it is easy to manufacture. If manufacturing is made easier, it automatically reduces the production cost as well. Therefore, it is an essential step in aluminum die casting product design.

We have to take into consideration various factors when carrying out DFM for aluminum die casting. So, you should provide a clear idea about the possible scope of application of your product. Then we can select an ideal material, design, and process based on it.

Selection of Material

It is crucial to select the proper material for casting. We have already discussed the common types of aluminum alloys used for casting along with their material properties and characteristics. Choose a material that fits your product’s quality and strength requirements.

Geometric Considerations

There are various geometric features to consider when designing a part for aluminum die casting. They can greatly reduce the complexity in production as well as the post-processing operations. We have briefly discussed some of the key geometric considerations below.

Draft: Draft or draft angle is the tapering of design perpendicular to the parting line. It is the most important geometric consideration in aluminum die casting design. Keeping a minimum amount of draft is essential to allow easier removal of the casting without risking damaging it.

Fillet and Radii: Internal and external sharp edges in a design are replaced with a proper amount of fillet and radii.

Undercuts: Undercuts in design should be avoided or reduced as much as possible. They can make a die casting process very complex. If it is not possible to eliminate all undercuts, they should be strategically placed along the parting line.

Ribs: Ribs are used to reduce the thickness of a section. Properly designed ribs can significantly reduce the product weight, yet increase the stiffness and strength of a casting.

Parting Line: It is the line along which two die halves meet. Carefully planning the parting line orientation can substantially reduce the difficulty of the casting.

Wall Thickness: Wall thickness in casting should be designed as thin and uniform throughout the part. Too thick walls increase part weight and delays cooling. While making it too thin can cause warping during solidification and prone to failure due to lack of stiffness.

Holes and Windows: Closely spaced holes or windows in a design can cause various issues during casting. So, adequate precautions should be taken to avoid casting defects.

Bosses: Bosses can be thought of as mounting points for the assembly of parts. When adding bosses in design, adequate fillet along with ribs should be provided.

Design for Assembly (DFA)

Larger parts are often divided into multiple components for casting them easily. Therefore assembling them after casting is also an important part of the manufacturing process. The objective of DFA is to design the parts in such a manner that simplifies the assembly process. Reducing the number of parts is the most common approach in DFA.

Cost Optimization Tips

The quality of your aluminum die casting products will largely depend on your budget. While seeking higher quality is essential, the processes involved to achieve the desired quality should also be within your budget. You need not choose materials and processes that will yield parts that exceed your requirements.

Therefore, you should carry out a detailed cost estimation and take into consideration the possible output before going into production. Properly maintaining the aforementioned design aspects will also simplify the manufacturing process and reduce the overall production cost.

If you wish to learn more about the design of aluminum die casting parts, we recommend you to check out our Aluminum Die Casting Design Guide. There we have included detailed design guidelines for various geometric features along with necessary figures and charts.

Chapter 8: Aluminum Die Casting Defects

Chapter-8-Defects

Aluminum die casting undoubtedly offers a wide range of benefits over most other manufacturing processes. Yet, the process can be subjected to various forms of defects. Therefore, minimizing the defects is the main challenge if you wish to enjoy the benefits it has to offer.

Below we have discussed the main types of defects that occur in aluminum die casting.

Gas Porosity Defects

It is one of the most common forms of die casting defect. Gas porosity is also referred to as air void or simply porosity. We can categorize porosity in die casting parts into different types depending on their form and location.

  • Blisters
  • Blowholes
  • Open Holes
  • Pinholes

Pouring Defects

It is the type of defect that is caused due to improper pouring of molten metal. The main reasons are usually insufficient molten metal or die temperature. Some common pouring defects are,

  • Short Fill / Misruns
  • Cold Shuts
  • Scaling

Shrinkage Defects

Shrinkage porosity may occur during the solidification of casting. It can cause large voids inside the die casting part. Therefore, the structural integrity is weak and is prone to failure under heavy loading conditions. Shrinkage defects are mainly of two types:

  • Open Shrinkage
  • Closed Shrinkage

Shape Defects

Some factors can distort the shape of the casting or make it go out of alignment. We can categorize them as shape defects. Some common shape defect includes,

  • Flash
  • Shift
  • Warping

Here, the shifting of two die halves causes flash to form along the parting line. Whereas warping results from differential solidification within a casting.

Metallurgical Defects

These types of defects mainly result due to an inconsistency in the chemical composition of a metal alloy. So, we can overcome such defects through modification of the chemical properties. Some common defects include,

  • Hot Tear
  • Hot / Hard Spots

Defects Due to Mold Design

A bad mold design or damaged mold can also contribute to the degradation of casting quality. Defects resulting from the mold includes,

  • Run Out
  • Swelling
  • Cracks
  • Scuffing

Apart from the aforementioned defects, many other types of minor defects can occur during the aluminum die casting process. You can read our detailed guide on various types of defects in die casting to learn more about them.

However, most die casting defects can be minimized or eliminated with the right manufacturing practices. You can check out our quality assurance technologies for aluminum die casting products to get some ideas.

Our advanced manufacturing techniques can nearly eliminate porosity and other common die casting defects. Moreover, We utilize the latest technology inspection devices to ensure top-notch quality and consistency for every casting.

Chapter 09: Aluminum Die Casting Products

We have previously discussed various industries that have a large demand for aluminum die casting. In this chapter, we have highlighted some common examples of aluminum die casting products to give you a clear idea of their scope of use.

EV Components: Electric-Vehicles (EV) are becoming increasingly popular due to their minimal impact on the environment. Manufacturers primarily use aluminum components for EV chassis construction to reduce the car’s weight, which increases energy efficiency. Some common aluminum diecast components used in EV includes,

  • Engine cylinder head, block & gasket
  • Transmission housing
  • Gearbox & motor enclosure
  • Heat sink
  • Battery Cover
  • Intake Tube
  • Car Rims
  • Chassis and other structural components, etc.

Aircraft Components: The lightweight of aluminum has made it an excellent material choice for manufacturing aircraft components. Most part of an aircraft including its fuselage is mainly made up of aluminum alloys. Diecast aluminum components are mainly used for structural and decorative components such as,

  • Window frame
  • Airline handrail
  • Engine housing
  • Brackets
  • Control equipment enclosure
  • Seat components, etc.

Marine Castings: Aluminum die casting products have superior corrosion and wear resistance. It is an essential property for any watercraft vehicle or ship as the marine environment is quite harsh on metals. Some common marine die casting products are given below:Chapter-6-Applications

  • Radar housing
  • Display frame & cover
  • Camera lamp cover
  • Heat sink
  • Pump housing
  • Display frame
  • Engine enclosure
  • Pedal component
  • Seal rings and housing, etc.

Decorative Hardware: The versatility of the aluminum die casting process allows the manufacturing of parts with complex details. Therefore, it is used to cast decorative hardware such as,

  • Gate and fence fittings
  • Door handle
  • Hydraulic door closer parts
  • Wall hangers
  • Brackets
  • Door lock enclosure, etc.

Headlight Buckets: Aluminum die casting headlight frames are also known as buckets. They are commonly used in the headlight of various types of vehicles such as cars, bikes, and even locomotives. The aluminum base also serves as a medium for heat dissipation.

Industrial Parts: Aluminum die casting products have large demand in the industrial sector. Most modern industrial equipment comprises a good number of aluminum diecast components. Some common industrial parts include,

  • Pump and motor housing
  • Rotor and stator
  • Impeller
  • Gear valve
  • Industrial fan housing
  • Power tool housing
  • Shaft Sleeve, etc.

Electro-mechanical Components: Electro-mechanical equipment has a greater focus on the thermal and electrical conductivity properties of metal parts. Therefore, aluminum diecast products are a great fit for this industry. Common electro-mechanical aluminum diecast parts are,

  • Rotor and stator
  • Cooling fan
  • Motor shaft
  • Heat sinks
  • Equipment housing, etc.

Electronic Device Components: The lightweight and superior thermal characteristics have made aluminum diecast products a viable choice for electronic devices such as phones, computers, cameras, etc. Some common diecast products used in electronic devices are listed below:

  • Electronic device Casing
  • Heat sink
  • Smartwatch outer bezel
  • Internal frame
  • Cooling fan, etc.

Medical Device Components: Medical equipment require a higher standard of production and inspection. The superior quality achievable by aluminum die casting products makes them an ideal choice for medical equipment. Some examples include,

  • Surgical lamp base & bracket
  • Patient bed gearbox housing
  • Medical device structural parts
  • Operation table gearbox
  • Robot arm & base, etc.

Plumbing Fixtures: Zinc die casting is more common for plumbing fixtures. But, aluminum die casting products’ high resistance to wear and corrosion makes them suitable for plumbing applications as well. Common applications include pipe fitting, elbow, thermal valve, etc.

Home Appliance Parts: Diecast aluminum parts are used in numerous home appliances. The lightweight aluminum and extended durability make it a convenient choice for household appliances. To name a few,

  • Ceiling fan cover
  • Vacuum cleaner body
  • Washing machine base, rotor
  • Washing machine brake wheel pulley
  • Speaker/Home theater casing
  • The table fan base, etc.

Kitchen Appliances & Cookware: Aluminum die casting products are widely used for the manufacturing of various types of kitchen appliances. As a good conductor of heat, aluminum is also an excellent choice for cookware. Moreover, the high corrosion resistance makes aluminum diecast products a suitable choice for the kitchen environment. Some examples include,

  • Cooking pots & pans
  • Cookware lid
  • Oven Interior & exterior
  • Blender & grinder frame
  • Gas stove & electric cooker frame, etc.

Panic & Fire Exit Hardware: Panic hardware used in emergency or fire exits used to be made with stainless steel. However, aluminum die casting has proven to be an excellent alternative to it. Some examples include,

  • Panic bar chassis
  • Push bar
  • Exterior door lever
  • Roller latch, etc.

Lighting Fixtures: Aluminum die casting is commonly used to produce decorative lighting fixtures. Moreover, aluminum diecast lamp bases are an essential component for modern led lamps as they serve the purpose of a heatsink as well. The thermal conductivity and heat dissipation characteristics of aluminum parts make them an ideal choice for lighting fixtures. Here are some examples,

  • Decorative lighting fixtures
  • LED street light housing
  • Medical lamp mounting base
  • Medical lamp bracket, etc.

HVAC Equipment Parts: Aluminum diecast products have many scopes of application in HVAC equipment. You will find diecast components in air compressors, condensers, and indoor units of air conditioning systems. They include,

  • condenser cooling fan
  • Scroll compressor spirals
  • Compressor cylindrical head
  • Vacuum pump heat radiating cover
  • Compressor housing, etc.

Decorative Fence & Straighteners: Aluminum die casting provides a convenient means for making decorative fence spears for home or agricultural use. They can be installed on the gate, railing, and boundary wall. The process is widely used for large volume production of diecast aluminum fence caps, connectors, and straighteners.

Chapter 10: Aluminum Die Casting Services

The global aluminum die casting market share has rapidly increased over the last few decades. Due to the increasing demand for aluminum diecast components in various industries, more and more manufacturers are growing their interest in aluminum die casting.

While every manufacturer will promise to deliver top-notch quality, not all of them succeed in doing so. In this chapter, we have highlighted some key services that should be provided by a die casting manufacturer to help you choose the right supplier for your business.

Basic Die Casting Services

Apart from the casting process using a cold chamber die casting machine, a complete aluminum die casting production involves various other processes. They can include,

  • DFM and PPAP Service
  • Die Casting Tooling
  • Die Casting Production
  • Post-Processing by CNC Machining
  • Surface Finishing, etc.

It would be best if you could find a manufacturer that provides all of the related services you would need for the production and processing of aluminum castings. Otherwise, dealing with multiple suppliers for casting, post-machining, and surface finishing would increase your production lead time coupled with various other issues during part handling.

Finding the Right Manufacturer for Your Business

We have shared some tips below that could help you look for a qualified aluminum die casting manufacturer.

  • Check out the online business directories of aluminum suppliers, and compare their pricing and ratings with each other to evaluate them.
  • The manufacturer should comply with international standards such as ISO 9001, IATF 16949, ISO 13485, etc. for aluminum die casting manufacturing.
  • You may also seek recommendations from your business contacts who have experience with aluminum die casting suppliers.
  • You can also visit international trade shows to get in touch with aluminum die casting suppliers from different parts of the world.

Outsourcing Diecast Components

Your options need not be limited within your country’s borders. In fact, you might even get a better deal from another country even with the shipping fees included. Moreover, if your country doesn’t have good aluminum die casting manufacturers, outsourcing them could be a viable solution.

If you wish to outsource your parts, then China could be a great option. China has the largest aluminum die casting industry in the world right now. Chinese manufacturers can offer higher quality parts at better pricing. And, it is possible due to having better technology, an abundance of natural and human resources in China.

Sunrise Metal is one of the leading aluminum die casting manufacturers in China. If you are looking for a reliable aluminum die casting manufacturer to outsource your parts, we invite you to have a look at our die casting services. We provide Rapid Prototyping, Die Casting Tooling, Die Casting, CNC Machining, and Surface Finishing services within our own facilities.

You can check out our capabilities as an aluminum die casting manufacturer to learn more about our services.

 Chapter 11: Future Development

Aluminum die casting is already a popular manufacturing process worldwide and is used by various industries. Yet, it continues to grow in popularity as new possibilities are added to this process with the advancement of technology.

In this chapter, we have discussed some of the emerging aluminum die casting technology that can leave a big impact on the manufacturing industry.

Giga Press

In the year 2019, aluminum die casting machine brand IDRA had launched the world’s first 6000T die casting machine and named it Giga Press. Shortly after that, LK Machinery introduced their IMPRESS-PLUS 6000T and 4000T die casting machines. In early 2021, LK introduced their DREAM PRESS series die casting machine with 9000T clamping capacity!

Tesla is one of the first companies to put this technology into action. They used the Giga Press to cast their latest Electric Vehicle, Model Y’s chassis. It has enabled them to cast more than 70 smaller components as a single homogeneous component. Thus, greatly reducing the time and cost involved in the part assembly.

Therefore, this technology has the potential to revolutionize the die casting industry as we know it. You can learn more about the Giga Press technology from our blog.

Predictive Analysis for Failure Detection

The current aluminum die casting production methods involve some manual procedures. But relentless research in this field has led to rapid advancement in the die casting industry and we hope to see more in the coming days. Digitization of die casting production is one of them.

One of the leading die casting equipment manufacturers, Bühler has been working on the digitization of the die casting process. They are using a machine learning algorithm for Predictive Analysis of die casting defects/failures. Moreover, they are running real-time performance tests by installing sensors inside the die casting cells.

CASTTRONICS Technology

The Fraunhofer IFAM has introduced the idea of digitation of aluminum diecast components. The idea is to install RFID transponders into a casting that can be used to permanently mark them. The parts can be uniquely identified by reading the data from the RFID anytime.

This will make die casting part identification and traceability a breeze for manufacturers. It can also be used for the measurement of parameters such as deformation, stress, and vibration in parts to get an early warning upon excessive loading. Moreover, it can be used to ensure the authenticity of parts and eliminate part plagiarism issues.

Chapter 12: Conclusion

We hope our aluminum die casting handbook was able to give you a proper understanding and insight into aluminum die casting. However, we only highlighted some of the important aspects of aluminum die casting here. But, it should be enough to give you a head start if you are new to aluminum die casting.

If you wish to learn more about the process, we have numerous blogs available on our site about aluminum die casting. We recommend you check them out. Also, you will find other blogs on our site about the latest manufacturing technologies.

Sunrise Metal is a professional aluminum die casting manufacturer. If you are interested in our services, you can contact our customer support team to discuss your aluminum die casting project. Also, you can get a get quote for your parts as well. We will respond to your inquiry within a day.

ALUMINUM DIE CASTING MANUFACTURER:

THE ULTIMATE FAQ GUIDE

Need the best solution for high volume or low to medium volume production of your products? Then you probably need an Aluminum Die Casting Manufacturer. They can give you the best manufacturing solution by balancing the production cost and quality of your parts.

Sunrise metal is a China Aluminum Die Casting Manufacturer with more than 10 years of experience in this field. We pride in our aluminum die casting capabilities, and we are confident to give you a fast and reliable solution for your project.

ALUMINUM DIE CASTING

 

What is aluminum die casting?

Process Aluminum Die Casting

Aluminum Die Casting is a widely used metalworking process for producing metal parts with great accuracy and durability. It is one of the most common production methods used by manufacturers all over the world.

Aluminum Die casting is mostly done in a cold chamber machine. The parts are made by injecting fluid aluminum into a die casting mold under high pressure using a plunger. However, there are several steps involved before and after casting the parts.

In order to ensure the highest quality for your parts, it is necessary to execute all the steps involved in mold castings with proper quality control. It is where an experienced and inexperienced manufacturer can play a big role in your project.

WHY SHOULD I CHOOSE ALUMINUM DIE CASTING?

There are various facts that make aluminum die casting an excellent solution for your products. Let’s have a look at its multitudes of benefits that can greatly enhance your experience with the manufacturing industry.

IT’S ECONOMICAL

Aluminum is the third most abundant element and the most abundant metal on earth. About eight percent of the earth’s crust consists of aluminum. Due to the abundance in nature, aluminum is very cheap and available all over the world.

Due to the low cost of raw material, aluminum has become extremely popular in the metalworking industry in a relatively short period.

LIGHTWEIGHT PARTS

Aluminum is almost three times lighter than cast iron. This fact alone has been a major driver for preferring aluminum parts. Now developers can make fuel-efficient vehicles. The use of metal in portable goods also became a common scenario as well.

The aerospace industry, in particular, has shown more interest in aluminum die cast parts. Its excellent strength-to-weight ratio makes it the ideal material for this job.

CORROSION RESISTANCE AND WEAR RESISTANCE

Aluminum die cast parts have exceptional protection against corrosion. It has good wear resistance too. So they are suitable for the corrosive environment and heavy loading conditions. It also minimizes the need for costly surface protection measures.

INCREASES PRODUCTION CAPACITY

Modern die casting methods have made the production of huge volume parts easier than ever. It can produce more parts at a particular time frame when compared against other methods of metalworking. So, it can significantly shorten the project lead time and increase your production capacity.

ENHANCED CONDUCTIVE PROPERTIES

Aluminum die castings offer great electrical and thermal conductivity. Aluminum parts exhibit exceptional heat dissipation characteristics, RMI-EFI shielding properties. So, they are extensively used for heat sinks, enclosures of many consumer electronic products.

WHY SHOULD I LOOK FOR AN ALUMINUM DIE CASTING SUPPLIER INSTEAD OF A ZINC OR MAGNESIUM DIE CASTING SUPPLIER?

Aluminum Die Casting vs Magnesium and Zinc Die CastingAluminum is a more commonly used cast metal for production compared to other non-ferrous metals such as zinc and magnesium. Here I have explained the features of zinc and magnesium die casting to help you decide when aluminum might be a better choice.

Zinc has material properties similar to that of aluminum. It has excellent strength, corrosion, and wear resistance. The raw material cost of zinc is almost equal to that of aluminum. It has a lower melting temperature and easier to cast than aluminum.

But zinc is several times heavier than aluminum. And zinc die casting parts can’t retain strength under high temperatures. So, even with some benefits, zinc is a less preferable option for production. However, zinc is used for producing small parts with intricate details.

Magnesium alloy products are lighter than aluminum, which is a desirable feature for any product. Magnesium parts have excellent machinability as well. But magnesium die casting manufacturers face some production difficulties.

First of all, magnesium parts are costlier than both zinc and aluminum. They are lightweight but tend to buckle under heavy loads. Magnesium is very susceptible to corrosion and wear as well. So, expensive coatings are required for magnesium die-cast parts.

Although there are some special applications for magnesium die cast products in aircraft and sports equipment. But, the slight reduction in weight accompanied by significantly higher production cost and durability issues is not something most preferable by a die casting company.

WHAT ARE THE TECHNOLOGIES USED BY ALUMINUM DIE CASTING MANUFACTURER?

There are different aluminum die casting technologies available. Each has its pros and cons. And not all of them are suitable for every task. Different die casting machines may offer better precision, faster production, or support casting of specific materials.

Some of the common aluminum die casting technologies are,

  1. Low-Pressure die casting
  2. High-Pressure die casting (Cold Chamber)
  3. Semi-solid die casting
  4. Vacuum die casting
  5. Squeeze die casting

LOW-PRESSURE DIE CASTING

Low Pressure Aluminum Die Casting

Porosity is an annoying issue for any die-cast parts. Low pressure die casting is a way of making aluminum parts with reduced porosity. Low-pressure die casting applies additional pressure during the casting. It allows more compact and defect-free parts

But its use is rather limited due to its slower casting cycle, which hampers the production capacity. So, most of the aluminum die casting vendors focus on its faster alternative, the high-pressure die casting.

HIGH PRESSURE DIE CASTING(COLD CHAMBER)

Cold Chamber Aluminum Die CastingWhen you demand high-quality parts and need them fast, high-pressure die casting is what you are looking for. It is more like a standard for aluminum die casting all over the world. That’s why mainly focused on this method in the rest of the guide.

However, there are two high-pressure casting processes, namely the hot-chamber and cold-chamber process. Aluminum has a high melting point. Due to this, it needs to die cast in a separate furnace and carry into the machine with a cold chamber setup.

SEMI-SOLID DIE CASTING

Semi-Solid Aluminum Die CastingThis aluminum die casting method handles metals that are in between a state of solid and liquid. Metals with such fluidity are called thixotropic fluids. This state of the metal is commonly known as semi-solid. It allows casting aluminum with higher precision.

The semi-solid casting procedure is used for making parts that have delicate applications. Mainly aircraft, medical devices, defense equipment, etc. are produced using the semi-solid die casting method.

VACUUM DIE CASTING

Vacuum-assisted AluminumVacuum die casting is an improved process. A pressure die casting equipment is often equipped with a vacuum mechanism to deal with the gas pores trapped inside a mold.

That’s why it is also known as vacuum-assisted high-pressure die casting too. It significantly minimizes casting defects involved during die casting and helps to reduce wastage.

SQUEEZE DIE CASTING

Aluminum Squeeze Die CastingIt is a simpler form of the high-pressure die casting process. It is often a cheaper alternative for making certain types of parts. It works by pouring a preheated die with molten aluminum and pressing it with another die to form the casting.

Squeeze die casting’s capabilities are rather limited. The casting cycle is usually slower than other methods.

If you want to know more about die casting, you can also visit the website of NADCA ( North American Die Casting Association ).

WHAT ARE YOUR MATERIAL OPTIONS FOR ALUMINM DIE CASTING?

The aluminum alloy used for casting is different from those used in machining or forging. Casting requires the materials to have good fluidity. Aluminum is alloyed with some elements to increase its fluidity properties and make it more suitable for die casting.

Aluminum Alloy Raw MaterialSome of the aluminum alloys we recommend and use ourselves are,

  1. A380
  2. ADC12
  3. AlSi10
  4. AlSi9Cu3 etc.

There are many other aluminum alloys available in the market too. You are welcome if you want us to use a particular alloy. We shall assess its suitability and arrange it for you if possible.

Looking to learn more about aluminum die casting alloys and their properties.

HOW CAN YOUR COMPANY REDUCE THE ALUMINUM DIE CASTING COST?

A significant cost associated with aluminum die casting is due to the high tooling cost. Because die casting tooling is done using CNC Machines. And CNC machining can be pretty expensive based on the complexity of the parts you are producing.

Certain design tips can greatly reduce machining time and cost for you. Some of them are discussed below.

MAINTAIN ADEQUATE DRAGT ANGLE

Draft Angle is the vertical inclination of outer walls along the parting line. It is provided to allow easier removal of casting from the die. You can see a similar feature in cupcakes as well. They have a larger diameter at the top and a smaller diameter on the bottom.

KEEP UNDERCUTS MINIMUM

Avoid undercuts in your custom-designed casting parts. If your product must include some undercuts, at least keep them aligned with the parting line. If undercuts are not appropriately placed, they complicate the casting process. Thus making it too expensive or impossible to cast.

AVOID SHARP EDGES

Any sharp edges in your dies make both machining and casting difficult. Machining sharp edges require CNC machines with high accuracy, which are also more expensive. And sharp edges in dies make it difficult to remove a casting and often damage the edges.

AVOID INTRICATE FEATURES

The tooling cost will drastically increase with the rise in complexity. Keep your design simple, and avoid unnecessary details. Try not to keep any deep pockets and avoid thick walls in your designs. Maintaining a uniform wall thickness is advised as well.

Following these guidelines can significantly simplify the machining process and reduce the production cost of aluminum die casting.

WHY ALUMINUM DIE CASTING PROCESS IS MOST POPULAR IN CHINA?

Compared with aluminum die casting manufacturers in India, China has the largest share in the production industry. And Chinese manufacturers are racing against each other to develop cost-effective and efficient production methods. High pressure die casting is by far the most widely used die casting technology in China.

As we stepped into the modern era, our demand for high-quality products kept on increasing. In order to meet the growing demand of end-users and manufacturers need a faster and more economical production approach.

With so many die casting companies available right now, assurance of the highest quality is of prime importance. High-pressure die casting is the most viable process for the mass production of aluminum parts. Some manufacturers are also adopting vacuum-assisted machines for better quality.

ALUMINUM DIE CASTING MANUFACTURER

WHAT IS THE INFLUENCE OF ALUMINUM DIE CASTING COMPANIES IN THE INDUSTRY?

Until the last century, steel and iron parts had dominated the metalworking industry. They were the most reliable option for high-quality parts with good strength. Back then, aluminum used to be a luxury metal due to a lack of proper technology for refining aluminum.

When aluminum was first discovered, its price was very high and even exceeded that of gold. In 1889, the first industrial process for aluminum production was invented. After that, aluminum prices rapidly dropped and became available worldwide.

The application of aluminum continued to grow in numerous products that relied on other metals before. Global aluminum production increased multi-folds by the mid-20th century. Aluminum became a common metal in everyday goods.

After the Second World War, another industrial revolution took place, which completely restructured the manufacturing industry. With the industrialization of advanced machining and casting tools, manufacturers began mass-production of aluminum parts.

After that, we were introduced to newer and better technology every decade. And modern computer numerical controlled machined further simplified every manufacturing method. Manufacturers started to look for cheaper and more efficient ways to produce parts.

With the advancement of technology, previous casting equipment was optimized for better production capacity with less cost. Now, aluminum die casting became one of the most cost-effective approaches for metal parts production.

New aluminum die casting suppliers are emerging every year. And the global market share of aluminum die casting is rapidly increasing worldwide. The industry is estimated to grow even more in the upcoming years.

WHAT SERVICES ARE OFFERED BY AN ALUMINUM DIE CASTING MANUFACTURER?

Aluminum die casting vendors in China usually provide multiple types of services associated with your die casting project. The number of services a supplier can provide simply demonstrates the ability to handle your project better.

Die casting suppliers usually offer the following type of services to their customers.

  1. Help Mold Design and analysis
  2. Provide Design for Manufacturing
  3. Die tooling with CNC machining
  4. Die casting
  5. Surface finishing for completed parts

These are commonly desired services that every customer wants from their supplier. Make sure the company you are partnering with has these services.

WHAT ARE THE QUALITIES OF A GOOD ALUMINUM DIE CASTING SUPPLIER?

It would be best if you verified some basic qualifications of the aluminum die casting factory before you hand over your important project to them.  Here are some important tips for you.

  1. Die casting vendors should have experienced engineers to help you optimize your design to suit their production facility.
  2. All necessary die casting equipment should be available in-house. There is equipment with varying accuracy rating. Make sure they have the right set of tools to meet your requirements.
  3. The foundries should have proper safety measures and hazard-free work environment. It provides added security for your projects from any unprecedented incidents.
  4. The latest technology machining tools should be available for handling complex tasks. Your die casting molds are one of the main determinants of the quality of your parts.
  5. Sometimes you may face unusual demand for your products. Your supplier should be well equipped to tackle your demands.
  6. Proper QA test equipment and expertise should be available. Often quality control can play a more critical role than the casting itself.
  7. Suppliers with an in-house surface treatment facility are preferable. It can save you both time and money wasted behind looking for a separate surface finishing company.

HOW TO FIND A RELIABLE ALUMINUM DIE CASTING MANUFACTURER IN CHINA?

China is dominating the manufacturing industry right now. Due to the abundant land resources, raw material availability, and substantial human resources; The production cost in China is much more reasonable than any other country in the world.

So, companies from abroad are depending on their China aluminum die casting manufacturers for the production of their products. But there is too many aluminum die casting manufacturers in China, and it is a tough decision to find the right supplier for your project.

So, when you are looking for an Aluminum die casting supplier in China keep the following facts in mind.

  1. Look up the online business directories for a supplier
  2. Check out recommendations from your business contacts
  3. International trade shows are a great opportunity as well. Review the recent trade shows to find a vendor that interests you
  4. Check out the company’s die casting equipment and quality management system
  5. Try to find any customer feedback about the company
  6. Make sure the company complies with the international standards

HOW TO MAINTAIN GOOD COOPERATION WITH ALUMINUM DIE CASTING MANUFACTURERS IN CHINA?

The Client-Supplier relationship is a crucial parameter for any business. There must be a proper understanding between them in order to get mutual benefits. Here are some tips that will help you maintain a good relationship with your supplier.

  1. Explain your project in detail. Communication is the key. Keep your terms and requirements clear. It can minimize the chances of conflict with the trade.
  2. If you are from a different country, respect the cultural differences each other.
  3. The employees may not be familiar with your language or have a different tone of speaking. Keep consideration for such occurrences.
  4. Meeting with your supplier will leave a positive vibe, and you will hopefully notice the differences later on.

Keep these tips in mind for a successful partnership with your vendor.

THE CAPABILITY OF SUNRISE METAL

WHAT ARE YOUR ALUMINUM DIE CASTING CAPABILITIES?

We are a leading aluminum die casting company in China. Our vast capabilities have enabled us to handle critical projects and provide on-time delivery. Here are some of our services and facilities that might be helpful for you.

ADVANCED DIE CASTING EQUIPMENT

Sunrise Metal’s Aluminum Die Casting Services

Our die casting shop is fully equipped with the latest technology aluminum die casting equipment. These are all cold chamber die casting equipment with different tonnage to match your precision requirement and size of the casting.

Some of the equipment is optimized to carry out a critical die casting project. We also have vacuum-assisted systems for reducing casting defects and offer higher quality parts.

HIGH PRECISION QA TEST DEVICES

We have advanced QA test devices that can measure the accuracy of your parts to a great extent. We can also detect any defects in your parts. We thoroughly check every part and make sure you get the absolute best quality from us.

VAST CHOICE OF ALLOYS

We allow popular aluminum alloys, e.g., ADC12, A380, AlSi9Cu AlSi10, etc. for production. You can also request us to use other aluminum alloys of your choice as well. We try our best to meet our client’s demands to the fullest.

CAN YOU DESIGN MY PARTS AND EXECUTE MOLD FLOW ANALYSIS FOR ALUMINUM DIE CASTING PRODUCTION?

Yes, we have experienced designers and the necessary hardware required to design parts for you. We are also capable of creating effective simulations for a mold flow analysis in advance.

So, our talented engineers can design your parts with a high degree of accuracy and optimize them for easier production. It helps to cut down aluminum die casting costs as well. Our advanced mold flow simulations can prevent inefficient design approaches and defects.

DO YOU HAVE MACHINING FACILITIES FOR ALUMINUM DIE CASTING TOOLING?

Sunrise Metal’s Aluminum CNC Machining Facility

Yes, we have CNC machining facilities! We pride in our first-class CNC machining capabilities that allow us to complete delicate die casting tooling projects. In fact, we have a dedicated tooling shop located in the Nantong prefecture of China.

Our CNC Machining capabilities include,

MACHINE CENTERS

Machine centers are convenient for their ability to carry out machining tasks with minimum human interactions. They are equipped with a tool magazine that can automatically change tools and perform multiple CNC machining processes.

MULTI-AXIS CNC MACHINES

We have the latest 5-Axis and 7-Axis CNC machines that are capable of carrying out intricate machining tasks that are often difficult or impossible with normal CNC Machines. So, we can confidently accept any tooling project.

ASSURANCE FOR ACCURACY

We have sophisticated instruments for measuring the precision of our work. Our Coordinate Measuring Machine can accurately calculate the geometric coordinates of the die casting mold and finished parts. So, you can rest assured about the accuracy of your parts.

CAN YOU PROVIDE SURFACE FINISHING FOR MY ALUMINUM DIE CAST PARTS?

Sunrise Metal’s Surface Finishing Service

Yes, we have our in-house surface finishing facility. We want to ensure an economical surface coating solution for you. So we provide most of the basic surface finishes such as cleaning, shot blasting, etc. within our factories.

We are also partnered with expert surface finishing agencies to avail more options for you. When you need more advanced surface finishes, we can arrange it for you. So, you can get powder coating, chrome plating, anodizing, nickel plating, etc. services from us too.

 

CAN YOU PROVIDE PPAP AND PATENT OUR WORK?

The Production Part Approval Process (PPAP) is an essential part of the automotive and aerospace industry’s product development process. We shall help you through the entire approval process. So, you don’t have to worry about it.

We also patent any unique manufacturing techniques used for a client’s project. We provide customized solutions to our clients that suit the requirements of their project. We are always looking forward to finding innovative production approaches.

CAN YOU UTILIZE ALUMINUM DIE CASTING RESOURCES FROM OTHER MANUFACTURERS?

We shall try our best to meet our client’s satisfaction. We will thoroughly assess any previous resources (e.g., die casting molds) you have from your last project. We will utilize the dies in our project if possible.

But do not worry if the resources you have are not in perfect shape and needs repairs. We provide die repair and maintenance services to utilize your old dies and preserve it for long term usage.

QUALITY CONTROL OF SUNRISE METAL

ARE YOU A CERTIFIED ALUMINUM DIE CASTING VENDOR?

Yes, Sunrise was issued the ISO 9001 certification in 2015 and the IATF16949 certification in 2016. These certifications signify our superior quality management systems. The ISO 9001 evaluates the quality management system of our company as a whole.

ISO 9001 certificate is given when a company fulfills the following criteria,

  1. All regulatory and statutory requirements stated in the manual are met
  2. Should have efforts towards improving the production efficiency and quality
  3. The quality management system should be strong and efficient
  4. Should have satisfactory customer service to develop business relationships
  5. Take proper measures for creating quality awareness among the employees

The IATF16949 certification is an international standard for quality management for the production of automotive parts. The following conditions must be satisfied to obtain this certification.

  1. Regulate the company services and product quality for improving customer satisfaction
  2. Should have continual development in existing production and quality control measures
  3. Proper technical expertise and QA test equipment to avoid any product defects
  4. Adopt processes with less waste generation and resource consumption
  5. Efforts towards enriching existing production facilities and workforce

HOW DOES SUNRISE METAL CONTROL THE QUALITY OF PRODUCTION PROCESS?

Sunrise Metal has a superior quality management system certified by ISO 9001 & ISO 13485 & IATF 16949. All our quality control processes abide by these international standards. We pride in our quality management and can guarantee maximum quality for the parts we produce.

We maintain optimum quality control in all stages of production. The complete quality control process of Sunrise Metal is explained below.

INSPECTION OF RAW MATERIAL

The incoming raw material properties are thoroughly tested with the help of a spectrometer. It helps us verify the raw material specifications by identifying the parameters such as,

  • Grade of the Alloy
  • Chemical Composition
  • Purity, etc.

No matter how good quality control measures are in motion in the later stages of production, optimum structural integrity and performance can’t be achieved without good raw material.

FAI AND LAI FOR DIE CASTING

Many suppliers will only conduct an FAI for die casting. But Sunrise Metal runs both First Article Inspection (FAI) and Last Article Inspection (LAI) during the manufacturing process. The FAI allows us to verify whether or not the manufactured part can meet your requirement.

But sometimes the die casting setup may deter from the initial condition. So, we carry out LAI and do random sampling of parts every two hours to ensure that the quality remains the same for the entire batch of parts.

OPTIMIZATION AND INSPECTION OF THE MACHINING PROCESS

Proper assessment of the parts is needed to ensure its manufacturability. Certain geometric features in a design can make it impossible or very difficult to machine. We provide effective design for manufacturing to avoid such issues.

We simulate the whole machining process beforehand to minimize the chances of errors during production. We also inspect the completed parts using CMM to measure the dimensions.

SURFACE TREATMENT QUALITY INSPECTION

The surface finishing provided to the parts is inspected using multiple inspection equipment. The color of the parts is assessed with a color meter. Thickness testing machines are used to verify the uniformity of coating thickness. We also have salt spray testers to assess the durability of the surface finishing.

OUTGOING INSPECTION

The finished parts are given a final check before they leave our premises. Performance and reliability assessment of the parts is carried out to ensure that the parts meet the specifications required by the customer.

Finally, the parts are given identification marks for ease of traceability. So, we can deal with product quality issues if any arises during usage. It allows us to deal with defective products faster and creates scope to enhance and predict quality for future production.

WHAT KIND OF QUALITY CONTROL INSTRUMENTS ARE USED AT SUNRISE METAL?

Sunrise Metal has dedicated instruments to ensure the optimum quality of any machined or cast parts along with the surface finishing. Some of the fundamental types of instruments available at Sunrise Metal are as follows.

DIMENSION MEASURING INSTRUMENTS

Coordinate Measuring Machine (CMM): CMM’s can accurately measure any geometric features by sensing discrete points on its surface with a probe. We have the leading-edge Zeiss Contura G2 CMM from the widely renowned Carl Zeiss brand at your service.

It allows us to take high-speed measurements with excellent accuracy. It also has an automatic scanning function. Its flexibility promotes better quality control of complex casting parts. Here’s a video of our employee operating the Zeiss CMM.

 

INTEGRITY ASSESSMENT INSTRUMENTS

Sunrise Metal Employee Checking the dimensions with Caliper

Caliper: We have calipers for taking measurements of standard tolerances. This allows us to take quick measurements that involve less time and labor.

X-ray Detector: We can identify any internal defects present in the casting parts with the X-ray detector. It allows us to deal with critical issues like cracks and porosity. So, we can maintain optimum quality control and ensure maximum structural integrity.

Sunrise Metal Employee Operating an X-ray Detector

Spectrometer: We can measure the spectral elements to verify the chemical composition of raw material and casting parts. This we can confirm the structural integrity of parts.

Hardness Testing Machine: It is a very useful instrument for measuring the mechanical strength of parts. So, we can ensure that our parts meet your required specifications.

SURFACE FINISHING TESTING DEVICES

Salt Spray Testing Equipment: We use this instrument for getting a relative measure of the corrosion resistance of surface finishes. It allows us to provide an estimation of the durability.

Thickness Testing Machine: We use a non-evasive testing device to check the thickness of the surface finishing. And we ensure that there are no irregularities in the parts.

There are many other quality control instruments available here as well such as,

  • Color Meter
  • Microscope
  • Leakage Test Equipment
  • Cleanliness Test Equipment
  • Projector, etc.

These help us assess the different physical and mechanical properties of the casting parts and the quality of the surface finishing.

HOW DOES SUNRISE CONTROL THE PART’S TRACEABILITY?

Traceability is a prerequisite for the quality management system of any company. It is a company’s ability to uniquely identify and track all processes from raw material collection to production, supply, sales, and consumption of their manufactured goods.

It allows the manufacturer to trace a part back to its origin from any stage of the production or distribution process. So, the company can acknowledge valid claims to recall their products in case the consumer encounters a defective product.

This helps build trust for a company as the consumer is aware of the source and quality control measures involved in manufacturing. It also increases the transparency and credibility of warranty terms of a part.

So, Sunrise metal values part’s traceability and treats it as an inherent element of the quality management system. We ensure proper traceability of parts through the following procedures.

ASSIGN BATCH CONTROL CARD

We have a Batch Control Card for every batch of production. All traceability parameters of that particular batch are recorded in the card. It allows us to keep track of important things such as,

  • Time of production
  • Shift leader in charge
  • Operators working on that batch
  • Production quantity, etc.

LETTERING AND LABELING OF INDIVIDUAL PARTS

Being able to uniquely identify each part is also important. So, we provide the parts with a unique identification number. For tracing die casting parts, we usually include lettering in the mold. We ensure traceability through labeling, printing, and laser etching as well.

Laser Etching Traceability InfThe following details are usually included for traceability,

  • An ID no. for each part
  • Work details
  • Part dimension
  • Inspection results, etc.

 

IS SUNRISE METAL A CONTINUALLY IMPROVED COMPANY?

Sunrise Metal has not achieved the recognition of a qualified aluminum die casting manufacturer overnight. We have been associated with the die casting business for more than ten years now. Through years of hard work and dedication of our employees, we have managed to make it this far.

ENHANCING TECHNICAL CAPABILITIES

We have a strong core competence backed by our superior engineering support and technological capability. Our extensive experience in this field allows us to provide the best manufacturing solution according to your economic constraints.

Our technological advancement also enabled us to substantially increase our production capacity. Our innovative production techniques can offer a higher yield rate with excellent repeatability.

OPTIMIZING PRODUCTION PRACTICES

We are relentlessly optimizing our manufacturing techniques to boost our workflow and gain more efficiency. We are gradually shifting towards automation to reduce manual labor and speed up the overall production process. This will also reduce the chances of man-made errors and reduce waste.

Our rapid manufacturing processes are already efficient enough to offer you half the usual lead time. But, we are trying to go beyond by introducing innovative production techniques that can meet your demands.

INVESTING IN INNOVATION

Sunrise Metal is continually investing to keep the crew and services updated with the latest technology. We use advanced manufacturing and inspection equipment to ensure maximum quality. We are also training our employees to advance their knowledge and experience.

Our R&D department is dedicated to introducing unique ideas to boost your production. We are committed to providing our customers with long term benefits through continuous innovation.

We aim to provide you a more fulfilling experience as you keep working with us. We are always improving, and we will always have something better to offer.

PARTNER WITH SUNRISE METAL

WHY SHOULD YOU CHOOSE SUNRISE METAL AS YOUR ALUMINUM DIE CASTING PARTNER?

Sunrise Metal Aluminum Sunrise Metal is one of the rising aluminum die casting manufacturers in China. With our excellent customer service and quality of work, we have provided excellent service to our customers worldwide.

Here are some of the remarkable things about our company which should convince you why we are the right partner for your project.

PRIORITY CUSTOMER SEVICE

Customer satisfaction is our highest priority. We aim for maximum customer satisfaction and try our best to help you with your project. You shall guide you in every step of your production and give you the best possible solution for your project.

ALL-IN-ONE SOLUTION

Sunrise Metal is not just an aluminum die casting factory. We have all sort of necessary production and quality control equipment required before and after casting. We have capabilities to help you from the beginning to completion of your project.

TWO DIE CASTING FACTORIES

Sunrise owns two die casting factories at Nantong and Kunshan. It should give you a good idea about the scope of our business. Our die casting facilities are enriched with the latest technology machines and are capable of handling complex jobs.

SOPHISTICATED QUALITY MANAGEMENT SYSTEM

We pride in our superior quality management system. Our strict quality control measures and corporate culture ensures the perfection of your work. We used advanced QA test equipment and employed a dedicated team for assuring the quality of your castings.

WIDE RANGE OF EQUIPMENT

We have a large collection of die casting equipment ranging from 280T to 800T. So we can carry out any small to medium volume operation with ease. We can maintain your required precision requirements as well.

STRONG COMMAND OF ENGLISH

It is a crucial trait for any China aluminum die casting company. We have to deal with many foreign clients, so all of our employees are instructed to maintain communication in English. We focus on giving you a welcoming feeling.

You can find out more about our services in other guide articles and blogs. You are welcome to check them out as well.

WHERE IS SUNRISE METAL’S ALUMINUM DIE CASTING FOUNDRY LOCATED IN CHINA?

Sunrise Metal factories are located in the Jiangsu province of China. We have a total of four foundries right now. Two of them are located in Nantong prefecture, and two of them are located in the Kunshan sub-prefecture.

Among these four, two of our foundries specifically carries out die casting operations. They are located in Nantong and Kunshan. Having two die casting facility at two cities help us operate easily and partner with more companies.

WHAT ARE THE PRODUCTION CAPACITY AND MINIMUM ORDER QUANTITY OF YOUR COMPANY?

We have enriched die casting facilities with modern equipment and experienced employees supervising the projects. Our properly executed supply chain management allows us to work efficiently and boost our production capacity.

We can produce up to 5000 aluminum parts on our current die casting facilities. We accept orders for any high-mix, low-volume projects as well. Unlike other big suppliers, we offer maximum dedication and customer support for all our customers.

So, startup companies and OEM/ODM can greatly benefit from our services.

DO YOU PROVIDE ALUMINUM DIE CASTING SERVICES FOR COMPANIES OUTSIDE OF CHINA?

Yes, we provide our aluminum die casting services worldwide. We have extensive experience for many foreign companies outside of China.

Till now, our client list extends over five hundred and still counting. Most of our customers are from Europe, Asia, and North America. We are eager to extend our reach to more customers and provide our services to other regions too.

HOW DOES SUNRISE CARRY OUT ALUMINUM DIE CASTING OPERATIONS?

Sunrise focuses on aluminum die casting manufacturing. That’s why we use cold chamber equipment for die casting aluminum parts. It is a variant of the high-pressure die casting process. It is used for materials like aluminum that has a high melting temperature.

Our die casting procedure is explained below for a better understanding.

3D MODELING OF PARTS

We need a model of your parts before we can get started. Submit the 3d model of your parts to get a quote of your project. You can also ask us to help you with your design.

MOLD DESIGN AND FLOW ANALYSIS

The next step is optimizing your Design for Manufacturing. Our engineers will design the die casting mold according to your parts design and run simulations. It helps to find out any possible defects associated with the design.

DIE TOOLING

Once the design is final, we proceed with creating the die casting injection mold. The molds are made using high precision CNC machines. It will offer excellent dimensional stability and accuracy for your die-cast parts. When the tooling is complete, assemble the molds in a die casting machine.

MATERIAL PREPARATION

An aluminum alloy of your choice will be selected based upon your requirements. We assess the quality of raw material and send it to a furnace for melting. We shall add proper additives if required, to improve the metal quality and get rid of impurities.

METAL INJECTION

The molten aluminum alloy is carried into the die casting machine using a ladle. The melt is poured into a cylinder and shot inside the die cavity using a plunger. The high pressure exerted by the plunger will ensure that the melt reaches every recess of the cavity.

CASTING REMOVAL

After injection, the fluid aluminum is left inside the mold to cool down and solidify. Once solid, the die is ejected, and casting is retrieved from the machine. Then the machine is sprayed with a water jet to prepare it for the next cycle.

FINISHING

The completed casting is trimmed down to remove sprue, runners, gates, flash, etc. It will also separate multiple aluminum parts that were cast together. Then you can choose to apply your desired type of surface finish for your parts.

WHAT TYPE OF COMPANIES HAVE YOU WORKED WITH BEFORE?

We have over 10 years of experience in the metalworking industry. Within the course of these years, we have worked for many companies worldwide. They were from different industries, and the parts were manufactured considering their possible applications.

Till now, the total number of clients served by us is more than 500. They were different regions of the world. We have successfully ensured high-quality parts and on-time delivery for each of our clients.

We have rich experience in die casting automotive parts and medical devices. We have also successfully supplied parts maintaining proper protection standards for the marine environment. We produced tons of parts for telecommunication devices and general consumer goods as well.

Companies served by Sunrise Metal

HOW CAN I REQUEST FOR QUOTE (RFQ) FROM YOUR COMPANY?

We need some basic details about your project to give you a probable estimate. You can either contact us through our online chat or mail us the required information. Some important information you should mention in your RFQ is as follows.

  1. Submit a 3d CAD file of your model. Attach any 2d model as well if available, they help us better assess the design. You can also contact us if you need help completing your model.
  2. Let us know your quality, precision, and strength requirements. If you have a preference for a particular aluminum alloy, mention that as well.
  3. Specify your order quantity and preferable deadline.

Write up the information in detail for an accurate quote. We shall get back to you as soon as possible.

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Request for Quote or Information
We would be glad to receive your request for quote.
Please email us your detailed requirements including 2D drawing & 3D Model and Quantity.
sales@sunrise-metal.com
  • +86-512-55291075
  • +86 13912651818
  • No 1456, Fushikang Rd, Kunshan City, Jiangsu, China
We are close to Shanghai PVG,SHA,& WUX Airportwe can arrange pick-up when you visit us.
Please fill out the form if you have any question.
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