Aluminum die casting is the method of choice for many automotive, industrial, and telecommunications products. It’s also often used to produce electrical, hydraulic, and lighting components. If you would like to know more about the high pressure aluminum die casting process and would like some help deciding if it is the right choice for your application, please don't hesitate to consult us about your customized project and we can sign a NDA with you.
What Materials Are Often Used in Die Casting Parts?
Zinc, aluminum, and magnesiumare the three main die casting alloys. They are normally non-ferrous and their mechanical properties vary greatly to fit almost every type of application a manufacturer may need. Not only can die cast alloys withstand high operating temperatures, but they are also fully recyclable.Aluminum alloys are ideal for a wide range of products due to their unique qualities. One of the most significant benefits of aluminum die casting is that it creates lighter parts—with more surface finishing options than other die cast alloys, including aluminum anodize.
High Pressure Aluminum Die Casting Process
Aluminum die casting is a manufacturing process that can produce geometrically complex metal parts using reusable die casting molds, called dies. The die casting process involves using a furnace, metal, die casting machine, and die. Aluminum alloys for die casting are melted in a furnace and then injected into the dies by the die casting machine. Once the liquid aluminum is injected into the dies, it rapidly cools and solidifies into the final aluminum die cast parts.
High pressure aluminum die casting is considered a non-expendable technique that can be repeatedly used to produce different shapes, sizes, and thicknesses of aluminum alloys for die casting. The aluminum die casting process also creates lightweight parts, maintains high operating temperatures, and provides excellent corrosion resistance for various industrial applications.
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The Advantages of Aluminum Die Casting
Aluminun die casting can manufacture complex-shaped and light components but with an excellent strength-to-weight ratio, giving it an edge over other metal molding castings and investment castings. Die casting parts with aluminum alloys can have a thickness as low as 0.5mm; the wall thickness of cast parts made with zinc can even be as low as 0.3mm.
Die casting parts feature excellent mechanical properties. As the liquid metal solidifies under high pressure, the product appears to be fine, compact, and crystalline. Die casting parts are rigid with high hardness and strength. Also, they have improved durability and high conductivity.
Die casting produces parts with high durability and dimensional accuracy. Even when exposed to harsh conditions, the parts maintain their dimensional accuracy over time. As a result, die casting is used in fabricating complex and internal parts of machines that require high standards of precision and accuracy.
Die casting maintains tighter tolerances over other casting processes. That is, parts are produced with minimal variations. The typical tolerance class of die castings is IT13~IT15 in GB/T 1800-2009. Higher precision can reach IT10~W 11. Therefore, the excellent dimensional accuracy of die casting avoids the need for machining and improves the utilization of the alloy.
Die casting parts have a smooth, consistent crystalline surface. Die casting process alloys molten metal alloy to fill up the dies and create the exact shape. Therefore, provided the die is well shaped and the process is in the right condition, the parts will be fine and smooth.
Because of making glossy parts, there is less need to proceed with additional post-processing operations, except for custom needs. What’s more, after die casting is done, products can be shipped off for delivery. This can reduce the total cycle production time.
Since the surface of die castings is often smooth with excellent mechanical features, die-cast parts often require less machining. In some cases, no machining at all. As a result, there is less need to spend on secondary operations. The ability of die casting to reduce post-processing costs helps ensure its cost-effectiveness.
Notably, die casting machines, molds, and other related types of equipment are quite expensive. However, mass production aids in better distribution of cost through the production process, thereby making the die casting process economical.