THE DEFINITION OF ALUMINUM DIE CASTING?
ALUMINUM DIE CASTING IS:
- One of the best processes to produce accurate aluminum diecast parts
- Involves forcing molten aluminum into a hollow cavity under high pressure
- High production capacity due to faster casting cycles
- Very economical for large-volume production
ALUMINUM DIE CAST PARTS HAVE:
- High corrosion resistance
- High electrical and thermal conductivity
- Good mechanical strength
Due to these alluring properties, it has become a widely adopted manufacturing process all over the world. Here is what you need to know about the aluminum die-cast process.
WHAT IS THE ALUMINUM DIE-CAST PROCESS?
We have classified the aluminum die cast process into the following steps for your easier understanding.
6 STEPS IF ALUMINUM DIE CAST PROCESS:
- Melting Alloy
- Die Preparation
Firstly, we melt the aluminum alloy in a crucible. During the process, we maintain a specific temperature depending on the type of alloy used. Additionally, we may use additives to improve raw material quality and reduce the chances of casting defects.
Then we thoroughly clean and lubricate the dies with a sprayer mechanism. After that, the die halves will form a cavity upon clamping. A ladle is then used to carry the molten metal from the crucible and poured into the die casting machine’s shot sleeve.
Then the molten aluminum is poured into the mold cavity under high pressure. The pressure is maintained until the casting has cooled down and solidified. When it is solid, the moving & fixed die will open and the ejecting system will eject the casting out.
However, there will be excess metal attached to the casting. We remove the extra portions using a trim die. The casting may also go through additional machining to incorporate features that were not possible or difficult with die casting.
ADVANTAGES OF ALUMINUM DIE CAST
Aluminum has many advantages. It is multiple times lighter than zinc and iron. Moreover, End-users always prefer to the portability and lightweight of products. So, aluminum has replaced the use of other heavier metals in many products.
Aluminum also has excellent material properties that are useful in many applications. The manufacturing process is faster and more economical than most other methods. So, suppliers all around the world have adopted the process.
The good points of the aluminum die-cast process:
- Rapid Production Rate
- Good Strength-to-Weight Ratio
- Excellent Dimensional Accuracy
- Lightweight Parts
- Good Corrosion Capability
- Great Electrical and Thermal Conductivity
- Can Operate in High Temperatures
- Easily form Intricate Details
- Extended Tool Lifetime
- Smooth Surface Finish
- Can be recycled
DIE CASTING ALUMINUM ALLOYS
Aluminum is alloyed with other elements to modify its material properties to suit a specific application. The following features can characterize casting aluminum alloys.
- High Fluidity
- Low Melting Temperature
- Good Machinability
- High Dimensional Stability
- Relatively Low Solidification Shrinkage
There are various casting aluminum alloys in the market. But each has a different percentage of alloying ingredients, which makes it suitable for a specific application. For example, having a more significant percentage of magnesium will make the parts lighter. However, the alloying elements can also compromise certain features of aluminum.
Some of the popular metal aluminum alloys include,
Here, A380 is the most commonly used aluminum alloy for diecast. Because it has a good balance of material properties. However, other alloys may excel in certain characteristics. For instance, A360 has better corrosion resistance, and A413 has better fluidity than other aluminum alloys.
ALUMINIUM DIE CAST APPLICATION
Aluminum die casting is popular in many industries. The aerospace and automotive industry, in particular, has a special preference for aluminum parts due to their lightweight. Different industries have varying standards for the type of aluminum alloy used. Some noteworthy applications include,
A typical industrial application of aluminum casting parts would be an engine component or appliance housing. Numerous end-user products such as cookware, phones, laptops, gadgets, etc.