If you are designing aluminum parts, make sure you consider the manufacturing process. Of all the forming processes for aluminum, die cast aluminum is the preferred solution.

Aluminum is a lightweight alloy with high dimensional stability. For this reason, aluminum die casting is a popular manufacturing process for creating complex shapes and designs with thin-walled cross-sections. As a result, they are a popular metal for a wide range of industries.This article will help you understand the basics of the die casting aluminum process. Let's take a closer look at the process

What is Aluminum Die Calcium Stabbing Process?

Die casting aluminum is a manufacturing method for making metal parts. Aluminum rods should be heated at high temperatures and completely melted, and then pressed into preformed mold cavities to create the desired metal part.

Aluminum Die Casting Process A cold chamber of a casting machine is used. The reason for melting aluminum in a cold chamber machine is that the high molten aluminum temperatures can damage the machine if the injection mechanism is flooded as in the hot chamber process.

Aluminum die casting process

In a cold chamber machine, the melting pots are separated and the molten aluminum alloy is then ladled from the pots into the molds under high pressure. After injecting the molten aluminum, it takes some time to solidify. You then need to separate the two halves of the mold to expose the aluminum casting.  

The final product has a smooth surface. Most of the time, the finished product does not require minimal machining and goes to the delivery stage very quickly. In addition, die casting molds are recycled to make identical parts before they are damaged. Therefore, aluminum die casting is an ideal manufacturing process for mass production. That's why manufacturers prefer die casting and it's popular across industries.

Advantages of Aluminum Die Casting

Aluminum castings have a wide range of surface finish options. Dimensional stability is another major advantage of the aluminum die casting process. In addition, they are so versatile that you can use them in almost any industry.

Die Casting Aluminum Parts

Here, we have listed some of the advantages of aluminum castings:

Finished product with excellent surface finish

Good tensile strength

Low cost raw material

Reduced porosity and impurities

Strong molecular structure ensures dimensional tolerances without micro-cracks

Thickness accuracy (up to less than 1.5 thickness)

Air tightness and pressure

Long life

Many alloys available with different chemical and mechanical properties

Very complex design parts can be produced

Common Die Casting Aluminum Alloys

There are several aluminum alloys commonly used for die casting. Some of them are:

A380

A390

A360  

A413

ADC-12

ADC-1

When preparing aluminum alloys for die casting, choosing the right alloy is your first priority. Let us help by providing you with some ideas on different common die casting aluminum alloy properties.

For example, A390 alloys are hard and have excellent wear resistance, but are less flexible than all other alloys. As such, they are suitable for applications such as automotive engine blocks.   

Aluminum A380 Die Cast Metal

On the other hand, A360 offers excellent airtightness and corrosion resistance. In addition, they have excellent fluidity when molten. This alloy is suitable for applications such as 5G communication boxes, automotive controller housings, and automotive oil sumps.

A380 alloys have excellent product and casting properties. As such, they are the choice of manufacturers for a wide range of applications. For example, A380 alloys are used in power tools, household furniture, electronic equipment chassis, transmission housings, engine mounts and many other applications.  

Aluminum Die Castings Alloy Properties

Aluminum alloys have a variety of advanced chemical and mechanical properties. They are highly resistant to corrosion and have high heat dissipation properties. In addition, the strength-to-weight ratio is a significant advantage.

These properties help mechanical engineers design aluminum die castings with great flexibility. Here are some of the attributes:

Lightweight design for easy movement

Corrosion resistance

Excellent strength-to-weight ratio

High operating temperature

Good stiffness

Finishing characteristics

RFI and EMI shielding

Excellent thermal conductivity

High electrical conductivity

Fully recyclable

Surface Finish Options Die Cast Aluminum

Parts made from the die-cast aluminum process require minimal machining. But nothing is perfect. Therefore, there are times when you need to perform surface finish operations for aesthetic and other functional purposes.

Here are some of the most popular surface finish options for aluminum castings.

Anodizing

Anodized die cast aluminum is an affordable option for making parts corrosion resistant and durable. It comes with a non-conductive protective layer on the part.

Aluminum is a highly conductive material, but the oxide layer has chemical and physical properties similar to ceramics and is electrically insulating; therefore, anodized die cast aluminum becomes non-conductive.

However, anodized aluminum exhibits limited conductivity through contact. This is due to the thin surrounding oxide layer. However, the conductivity is very low compared to untreated aluminum. Therefore, if your application requires conductivity through aluminum, you should choose another surface treatment option.

Anodized die-cast aluminum

Powder Coating

Powder coating is one of the most popular surface treatments for aluminum die castings. It occurs at higher temperatures and is relatively difficult to do. However, this method makes the parts scratch resistant. In addition, you will get a wide variety of colors, textures and gloss levels.

Chemical Film

This is another popular finishing option for aluminum die cast materials. You can apply it in a variety of ways, such as spraying, dipping process, brushing, and more. The only difference is that it is electrically conductive.

Read more about Metal Finishing Options.

Applications Aluminum Castings

Aluminum has some excellent mechanical advantages. As a result, you will see them in many applications. For example, they are an integral part of the automotive and construction industries.

According to a report, Aluminum Castings Market Size $5.05 Billion 2019 USD with an estimated compound annual growth rate (CAGR) of 2027% from 6.4 years to 2000. More industries will join the community and develop new applications.

Here are some of the top applications for aluminum die casting.

Construction

You'll see aluminum in roof superstructures, window frames and more. Today, large structures such as bridges and commercial buildings also use die-cast aluminum components during construction.

Automotive

Aluminum is lightweight, which is an essential feature of modern cars. As a result, you'll see a wide range of applications for these alloys in the automotive industry. From engines to body parts, they are everywhere.

Different automotive parts made from die-cast aluminum

Electronics industry

No other industry has risen to prominence faster than the electronics industry over the past two decades. These industries have excelled in consumer product innovation. Aluminum has been instrumental in the production of these consumer goods.

From smartphones to 5G network housings, die-cast aluminum alloys have played an important role in this development.

Furniture

Aluminum has a high strength-to-weight ratio and is resistant to corrosion. In addition, they are not that expensive. For this reason, the furniture industry uses aluminum alloys for a wide range of home and office furniture.

For example, you can see that more and more chairs are made of die-cast aluminum. In addition, many important furniture parts are made of aluminum, such as door locks, hinges, handles and other aluminum accessories.

Aerospace industry

Like the automotive industry, the aerospace industry requires an alloy that is lightweight and impact resistant. In addition, the aerospace industry requires complex tooling and high-strength structural components. As a result, aluminum die casting materials are used in various parts of aircraft.

A number of aerospace parts are made from die-cast aluminum, such as aircraft engine piston heads, cargo loading housings, fuel system parts, aircraft distributor cap housings, as well as lighting fixture parts and electronic housing lag ring parts.

Aluminum Die Casting Design - 3 Factors to Consider

Manufacturers need to take a number of steps through the aluminum die casting process.

Mold Design

The first big thing is mold design. The design needs to be efficient so that you can inject molten aluminum and remove the built part effortlessly. Every mold has a parting line (the line that separates the two halves) that the designer should consider before completing the design.

Injection Point Location

The next important consideration is the location of the injection points. You can add multiple injection points. This can be done if there is any chance of solidifying the molten aluminum before it reaches each gap in the mold. In addition, it helps to design in cavities.

Chamber Wall Thickness

The wall thickness of the part is another factor you should consider. With the help of automation and precision machines, there is no minimum thickness level. However, for better results, it is better to choose a consistent thickness for better results.

Aluminum Die Casting Parts Line: Custom Aluminum Die Castingg Prototypes and Parts

Aluminum Die Casting Cost

The aluminum die casting process is a relatively inexpensive manufacturing process. The cost depends on a variety of factors. The first is the initial tooling cost. Tooling costs for this process can range from $7,000 to $75,000, thus adding to the total price of the die casting process. But because die casting is a repetitive process, it becomes more cost effective when you are producing large quantities.

Second, it's difficult to determine the exact cost of die casting without knowing the product specifications. It depends on the size of the mold, whether the profile created is hollow or solid, and the complexity of the cross-section.

Third, costs will vary depending on the type of machine and worker. The curing process for a large number of features will take longer, which will also affect the cost. Additionally, complex moving parts will affect the opening and closing events of the machine, which will also add to the cost.

RapidDirect - Your Cost-Effective Aluminum Die Casting Service Provider

RapidDirect provides precise custom aluminum die casting services with fast turnaround times. You can fabricate aluminum parts in a variety of sizes - from a few grams to your preferred size.

We have the industry-experienced staff and engineering, strategy, and creative experts to complete your project just the way you want it. From prototyping to mass production, we offer you the most affordable services.

Our workshop is equipped with automated machines and robots built with futuristic technologies.

We can achieve tolerances as low as ± 0.004 inches (0.1 mm) for your die-cast aluminum parts. We are ISO 9001:2015 certified and manufacture your die cast parts to industry standards.

Here's how you can benefit from Rapid Direct.

Up to 30% price reduction

Manufacture parts to customer requirements.

Our expert professional engineers always give you the best manufacturing feedback based on your design.

Powerful ability to accelerate the design-to-part cycle

You can upload your design files to our platform for a quick quote and free DFM analysis.

High inspection standards to ensure quality parts.

Experience working with Tesla, Toyota, NASA, Emerson, Emirates, and many other large brands and organizations around the world.

Try RapidDirect today!

All information and uploads are secure and confidential.

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Conclusion

Die casting can be an expensive method if you don't use a lot of parts. However, if you are dealing with large quantities, die casting is the most cost-effective process. Due to its unique properties, manufacturers choose aluminum over other metals. Additionally, the lower material costs help manufacturers increase their profit margins.

We hope you found this article helpful. Rapid direct's specialized die casting services ensure that you get the exact part from your design. We also offer price reductions to meet the needs of our global customers. If you have any questions, drop us a line. Don't forget to ask for a quote on any of your projects.

Frequently Asked Questions

What is the difference between aluminum die casting and sand casting?

The most significant difference between die casting and sand casting is the material used to make the mold. Aluminum castings use molds made from aluminum alloys. Sand casting, on the other hand, uses molds made of sand.

Sand casting can handle more complex designs. On the other hand, die casting offers higher dimensional accuracy and speed.

Another important difference is that sand casting produces thicker walls while die casting can produce thinner walls. Therefore, sand casting is not suitable for small parts.

Production speed is another important difference between the two technologies. Die casting molds are a complex task that takes a lot of time. On the other hand, sand casting molds are a simple process that takes less time than die casting.

Die casting is ideal for mass production, such as when you need thousands of parts. However, sand casting is perfect for smaller production runs of 100-150 units.

We have a detailed guide to Die Casting vs Sand Casting.

How expensive is aluminum casting?

Aluminum casting is one of the most cost-effective processes for die casting metals. While die casting molds take more time, you can make thousands of units from a single mold. The more you produce, the lower your unit price. Aluminum is much cheaper than stainless steel and slightly more expensive than carbon steel.

How fast is the die casting process?

Die casting is an automated casting process. It takes a while to create a mold. But the molds can solidify aluminum alloys quickly. Since it is an automated process, the machine can make many units without interruption. Therefore, die casting is a fast process, especially if you are making a large number of parts.

Business Contact: Zach Pan, Sales Manager

Zach Pan, Sales Manager, Email: pan@casting-aluminum.com