What is Aluminum Die Casting
Aluminum die casting is a kind of die casting part. It is a pressure casting process by using a casting mold to pour the heated liquid aluminum or aluminum alloy into the inlet of the die casting machine. After die-casting by a die-casting machine, aluminum parts or aluminum alloy parts of the shape and size restricted by the mold are cast. Such parts are called aluminum die castings.
Advantages of Aluminum Die Casting
- Good Strength-to-Weight Ratio
- Great Corrosion-resistant
- Highly Electrical Conductivity
- Lightweight and Durable
- Have a good stiffness and strength-to-weight ratio
- Short Lead Time
- Fully Recyclable and Reusable in Production
Aluminum die casting Applications
Alloys of aluminum are used in die casting more extensively than alloys of any other base metal. About 2.5 billion dollars worth of aluminum alloy die castings are produced each year in the United States alone. The die casting process consumes almost twice as much tonnage of aluminum alloys as all other casting processes combined.
Die casting is especially suited to the production of large quantities of relatively small parts. Aluminum dies castings weighing up to about 5 kg are common, but castings weighing as much as 50 kg are produced when the high tooling and casting-machine costs are justified.
With die casting, it is possible to maintain close tolerances and produce good surface finishes. Die castings are best designed with uniform wall thickness: minimum practical wall thickness for aluminum alloy die castings is dependent on casting size.
Aluminum die casting usually are not heat-treated but occasionally is given dimensional and metallurgical stabilization treatments.
Die castings are not easily welded or heat-treated because of entrapped gases. Special techniques and care in production are required for pressure-tight parts. The selection of an alloy with a narrow freezing range also is helpful. The use of vacuum for cavity venting is practiced in some die casting foundries for the production of parts for some special applications.
Aluminum die casting alloys
Approximately 85% of aluminum alloy die castings are produced in aluminum-silicon-copper alloys.
Alloy 380.0 and its several modifications. This family of alloys provides a good combination of cost, strength, and corrosion resistance. Together with the high fluidity and freedom from hot shortness that is required for ease of casting. Where better corrosion resistance is required, alloys lower in copper, such as 360.0 and 413.0 must be used.
Alloy 518.0 is occasionally specified when the highest corrosion resistance is required. This alloy, however, has low fluidity and some tendency to have hot shortness. It is difficult to cast since its cost in casting is higher.
Typical applications of die cast aluminum alloy castings:
| Alloy 380.0 | Lawnmower housings, gear |
| Alloy A380.0 | Streetlamps housings, typewriter frames, dental equipment |
| Alloy 360.0 | Frying skillets, cover plates, instrument cases, parts requiring corrosion resistance. |
| Alloy 413.0 | Outboard motor parts such as pistons, connecting rods, and housings |
| Alloy 518.1 | Escalator parts, conveyor components, aircraft, and marine hardware and lit tings. |
Secondary Operations
| Trim Presses from 5-50 tons | CNC Milling | CNC Turning | Grinding | Automatic Tapping |
| Steel Shot Blasting | Vibratory Tumbling | Embossing | Wire Wheel | Assembly |
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