If you are designing an aluminum part, be sure to consider the manufacturing process. Among all aluminum forming processes, die-cast aluminum is the preferred solution.
Aluminum is a lightweight alloy with high dimensional stability. Therefore, aluminum die casting is a popular manufacturing process for creating complex shapes and designs with thin-walled sections. Therefore, they are a popular metal in various industries.
This article will help you understand the basics of the die-cast aluminum process. Let’s take a deeper look at this process.
Die casting aluminum is a manufacturing method for making metal parts. The aluminum rod should be heated at high temperatures and completely melted, and then pressed into a preformed mold cavity to manufacture the required metal parts.
The aluminum die casting process uses the cold chamber of the casting machine. The reason for melting aluminum in a cold chamber machine is that the high molten aluminum temperature can damage the machine if the injection mechanism is flooded like in the hot chamber process.
In a cold chamber machine, the melting pot is separate and the molten aluminum alloy is then scooped from the pot into molds under high pressure. After molten aluminum is injected, 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 requires minimal processing and reaches the delivery stage quickly. Additionally, die-cast molds are recycled to make identical parts before they become damaged. Therefore, aluminum die casting is an ideal manufacturing process for mass production. That is why manufacturers prefer die casting it and it is popular in various industries.
Aluminum castings are available in a wide range of surface finish options. Dimensional stability is another advantage of the aluminum die-casting process. Additionally, they are so versatile that you can use them in almost any industry.
Here we list some of the advantages of aluminum castings:
· Finished product with excellent surface finish
· Good tensile strength
· low cost raw materials
· Reduce porosity and impurities
· Strong molecular structure ensures dimensional tolerances without microcracks
· Thickness accuracy (can reach less than 1.5 thickness)
· Air tightness and pressure
· longevity
· Many alloys are available with different chemical and mechanical properties
· Can produce parts with very complex designs
There are several aluminum alloys commonly used in die casting. Some of them are:
· A380
· A390
· A360
· A413
· ADC-12
· ADC-1
When preparing for aluminum die casting, choosing the right alloy is your first priority. Let us help you by giving you some ideas on the different common die-cast aluminum alloy properties.
For example, A390 alloy has high hardness and excellent wear resistance, but is less flexible than all other alloys. Therefore, they are suitable for applications such as automotive engine blocks.
On the other hand, A360 has excellent air tightness and corrosion resistance. In addition, they have excellent flow properties when melted. This alloy is suitable for 5G communication boxes, car controller casings, car oil pans, etc.
A380 alloy offers excellent product and casting properties. Therefore, they are a widely used choice among manufacturers. For example, power tools, home furniture, electronic equipment chassis, transmission housings, engine mounts and many other applications use A380 alloy.
Aluminum alloys possess 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 properties:
· Lightweight design, easy to move
· Corrosion resistance
· Excellent strength to weight ratio
· high operating temperature
· good stiffness
· Finishing characteristics
· RFI and EMI shielding
· Excellent thermal conductivity
· High conductivity
· Fully recyclable
Parts made from die-cast aluminum require minimal machining. But nothing is perfect. Therefore, sometimes you need to perform surface finish operations for aesthetic and other functional purposes.
Here are some of the most popular finish options for aluminum castings.
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 parts.
Aluminum is a highly conductive material, but the oxide layer has ceramic-like chemical and physical properties that are electrically insulating, so anodized die-cast aluminum becomes non-conductive.
However, anodized aluminum exhibits limited conductivity through contact. This is because the surrounding oxide layer is very thin. But the conductivity is very low compared to untreated aluminum. Therefore, if your application requires electrical conductivity through aluminum, you should choose other surface treatment options.
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. But this method makes the parts scratch-resistant. Plus, you'll get a wide variety of colors, textures, and gloss levels.
This is another popular finish option for aluminum die-cast materials. You can apply it in various ways such as spraying, dipping process, brushing, etc. The only difference is that it is conductive.
Read more about metal finishing options .
Aluminum alloys have some excellent mechanical advantages. Therefore, you will see them in many applications. For example, they are an integral part of the automotive and construction industries.
According to a report, the aluminum castings market size was USD 5.05 billion in 2019 and is expected to grow at a compound annual growth rate (CAGR) of 6.4% from 2000 to 2027. More industries will join the community and develop new applications.
Here are some of the top applications for aluminum alloy die casting.
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 their construction.
Aluminum alloy is lightweight, which is also a basic feature of modern cars. Therefore, you will see a wide range of applications for these alloys in the automotive industry. They are everywhere from engines to body parts.
No other industry has emerged faster than the electronics industry over the past two decades. Consumer product innovation in these industries stands out. Aluminum has always played an important role in the production of these consumer products.
From smartphones to 5G network casings, die-cast aluminum alloys play an important role in this development.
Aluminum has a high strength-to-weight ratio and is corrosion-resistant. Plus, they're not that expensive. Therefore, the furniture industry uses aluminum alloys to manufacture a variety of home and office furniture.
For example, you can see more and more chairs made of die-cast aluminum. In addition, many important furniture parts are made of aluminum parts, such as door locks, hinges, handles and other aluminum accessories.
Like the automotive industry, the aerospace industry requires an alloy that is lightweight and impact-resistant. Additionally, the aerospace industry requires complex tooling and high-strength structural components. Therefore, aluminum die-cast materials are used in various parts of the aircraft.
Some aerospace parts are made of 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 retention ring parts.
Manufacturers need to take some steps with the aluminum die casting process.
The first big thing is mold design. The design needs to be efficient so that you can pour in molten aluminum and get the built parts out effortlessly. Every mold has a parting line (the line that separates the two halves) that designers should consider before finalizing their design.
The next important consideration is the location of the injection point. You can add multiple injection points. If there is any chance of solidifying the molten aluminum before reaching every gap in the mold, do this. Additionally, it helps with cavities in the design.
The wall thickness of the part is another factor you should consider. With automated technology and precision machines, there is no minimum thickness level. But for better results, it is better to choose a consistent thickness for better results.
The aluminum alloy die-casting process is a relatively cheap manufacturing process. Cost depends on various factors. The first is the initial tooling cost. Mold costs for the process range from $7,000 to $75,000, thus increasing the overall price of the die casting process. But since die casting is a repetitive process, it becomes more cost-effective when you go into high-volume production.
Second, it is difficult to determine the exact die casting cost without knowing the product specifications. This depends on the mold size, whether the profile created is hollow or solid, and the complexity of the cross-section.
Third, costs vary depending on the type of machine and worker. The curing process for large numbers of features will take longer, which will also impact cost. In addition, complex moving parts affect the opening and closing events of the machine, which also increases costs.