Aluminum Die Cast Alloys: Complete Guide for Buyers

Aluminum die casting is one of the most widely used manufacturing methods for producing lightweight, strong, and precise parts. By injecting molten aluminum alloys under high pressure into a steel mold, manufacturers can create complex geometries with excellent surface finishes. For buyers, understanding aluminum die cast alloys is critical—not only to ensure performance in the end product but also to balance cost, durability, and supply chain reliability.

This guide explains the characteristics of aluminum alloy die casting, compares common alloys like A380, A360, ADC12, and AlSi10Mg, and shows how buyers can evaluate the best choice for their projects.

Key Characteristics of Aluminum Die Cast Alloys

Aluminum cast alloys share several fundamental advantages that explain their widespread use across industries:

• Lightweight – Most aluminum die cast alloys have a density around 2.7 g/cm³, reducing overall component weight, which is especially valuable in automotive and aerospace applications.
• High Strength and Durability – Even though aluminum is light, die cast alloys such as A380 or A360 provide strong structural integrity and toughness at operating temperatures.
• Corrosion Resistance – Alloys with higher silicon and copper content resist atmospheric and chemical corrosion, extending service life.
• Thermal and Electrical Conductivity – Aluminum is an excellent conductor, making alloys like A383 ideal for electrical housings and heat sinks.
• Dimensional Stability – High-pressure die casting ensures tight tolerances and repeatability for complex parts.
• Surface Finish – Die cast aluminum typically requires minimal post-processing, providing smooth surfaces suitable for painting, anodizing, or powder coating.

In short, die cast aluminum material properties combine low weight, durability, and excellent machinability, which make them an attractive alternative to steel or plastic for many buyers.

Common Aluminum Die Cast Alloys

Different projects call for different alloy families. Below are the most widely used aluminum die cast alloys list:

A380 Aluminum Alloy

A380 is by far the most commonly used aluminum die casting alloy worldwide. It combines excellent mechanical properties, good corrosion resistance, and cost-effectiveness. Buyers choose A380 because it balances strength and lightweight properties, making it suitable for automotive housings, brackets, and electronic enclosures. Its fluidity allows for complex shapes, while its machinability reduces secondary costs. For procurement managers, A380 is often the “default” alloy due to global availability and predictable performance.

A360 Aluminum Alloy

A360 offers superior corrosion resistance compared to A380, along with higher ductility at elevated temperatures. This makes it a preferred choice for telecom housings, marine equipment, and parts exposed to moisture or chemicals. However, it can be more difficult to cast, requiring experienced foundries with strict process control. Buyers should be aware that tooling and cycle time may be slightly more demanding with A360, but the long-term reliability in harsh environments justifies the investment.

A390 Aluminum Alloy

A390 is selected when high wear resistance and hardness are required—such as in engine blocks, automotive pumps, and industrial machinery. Its high silicon content provides strength but reduces elongation, making it less ductile. For buyers, this means A390 parts are harder to machine and more prone to brittleness if not properly designed. Still, in high-load applications, A390 can significantly extend component life and reduce warranty costs.

ADC12 (Asian Standard)

ADC12, commonly used in Japan, China, and across Asia, is similar to A383. It is valued for stable casting performance, low porosity, and cost efficiency. Electronics manufacturers often prefer ADC12 for housings and heat sinks because of its balance of strength, corrosion resistance, and surface finish. For international buyers sourcing in Asia, ADC12 offers the advantage of local supply chains, lower cost, and proven reliability.

AlSi10Mg

AlSi10Mg is a high-silicon alloy that offers excellent casting performance with good strength-to-weight ratio. It is increasingly used in aerospace and high-performance automotive parts. Compared to A380, AlSi10Mg provides better fatigue strength and corrosion resistance but comes with higher material cost. For buyers, it represents a premium option when performance is more critical than initial price.

Special Consideration: 6061 and 7075

Buyers often ask whether 6061 or 7075 aluminum—popular wrought alloys—can be die-cast. In practice, these alloys are not suitable for conventional high-pressure die casting due to poor fluidity and hot-cracking tendency. They are better used in extrusion or forging. While technically possible in limited cases, buyers should be cautious: choosing 6061 or 7075 for die casting can result in high rejection rates and elevated TCO.

Among these, A380 aluminum alloy composition is the global standard, accounting for nearly half of all die cast aluminum parts due to its versatility and balance of properties.

Alloy Comparison: Properties and Composition

Buyers often need hard data to compare alloys. Below is a simplified cast aluminum alloys list showing density, tensile strength, elongation, and typical applications:

This table gives buyers a quick reference for die cast aluminum material properties—showing not just chemistry but also what that means in real-world use.

Applications of Aluminum Die Cast Alloys

Because of their mechanical and economic benefits, aluminum die cast alloys are used across industries:

Automotive Industry

The automotive sector is the single largest consumer of aluminum die cast alloys. Buyers in this industry value weight reduction, dimensional accuracy, and the ability to produce large volumes with consistent quality.

• Typical Parts: Engine blocks, transmission housings, EV battery enclosures, structural brackets, steering components.
• Alloy Choices:
  • A380 is the go-to alloy for housings and brackets due to its balance of strength and castability.
  • A390 is often specified for high-wear components such as engine cylinders and pumps.
  • AlSi10Mg is used in premium EV structural parts requiring high fatigue resistance.
• Buyer Insight: Selecting the right alloy directly affects fuel efficiency and EV range. For high-volume OEMs, A380 remains cost-effective, but for demanding load-bearing components, A390 or AlSi10Mg may reduce warranty claims and lifecycle costs.

Aerospace and Defense

In aerospace, weight savings are critical, but performance cannot be compromised. Buyers focus on alloys that provide high strength-to-weight ratios and resistance to fatigue.

• Typical Parts: Structural housings, brackets, UAV components, satellite frames.
• Alloy Choices:
  • AlSi10Mg is widely used for aerospace castings due to its high strength and corrosion resistance.
  • A360 is chosen for parts exposed to environmental extremes.
• Buyer Insight: Aerospace buyers require not just alloy selection but also certified traceability and compliance testing (spectral analysis, fatigue testing). This increases sourcing complexity, making supplier reliability a key factor in alloy choice.

Telecommunications and Energy

Telecom and renewable energy systems rely heavily on die cast aluminum for its electrical and thermal conductivity.

• Typical Parts: RF housings, telecom antennas, solar inverter housings, wind turbine gear casings, LED heat sinks.
• Alloy Choices:
  • A360 for high corrosion resistance in outdoor equipment.
  • ADC12 for electronic housings requiring cost-effective precision.
• Buyer Insight: For energy buyers, alloy choice impacts not only durability but also thermal management efficiency. Reliable alloys help reduce overheating in electronic systems and lower maintenance costs in remote installations.

Consumer Electronics and Appliances

Electronics manufacturers prioritize aesthetics, thin-wall capability, and cost efficiency. Aluminum die cast alloys are valued for their ability to create slim, durable designs.

• Typical Parts: Laptop frames, smartphone housings, LED lighting fixtures, appliance casings.
• Alloy Choices:
  • ADC12 and A383 dominate due to their excellent fluidity and stable mechanical properties.
• Buyer Insight: Procurement managers in this sector must balance mass-production cost with cosmetic requirements. ADC12 is often chosen because it produces smooth surfaces suitable for powder coating or anodizing without extensive machining.

Industrial Machinery

Heavy-duty industrial equipment requires alloys with strength, wear resistance, and stability under stress.

• Typical Parts: Hydraulic pump housings, compressor bodies, gear housings, robotic arms.
• Alloy Choices:
  • A380 for general machinery housings.
  • A390 where high hardness and wear resistance are essential.
• Buyer Insight: In industrial sourcing, alloy choice is often driven by downtime risk. Selecting stronger alloys may reduce part replacement cycles, directly improving total cost of ownership (TCO).

These applications highlight why buyers searching for the best aluminum die cast alloys need to align material choice with the functional requirements of their end products.

Buyer Considerations: Choosing the Right Alloy

For procurement teams, the challenge is not just technical—it’s also about balancing cost, delivery, and performance.

Choosing the right aluminum die cast alloy is not simply a matter of strength; buyers must also evaluate cost, machinability, corrosion resistance, and long-term performance. Below are the most common questions procurement teams raise when sourcing alloys, with practical answers.

What is the most common aluminum die cast alloy?

Across global markets, A380 is the most widely specified alloy. It offers an excellent compromise between strength, corrosion resistance, and castability. For high-volume projects—such as automotive housings or consumer product enclosures—A380 provides stable performance at competitive cost. This explains why it dominates the aluminum die cast alloys list across North America, Europe, and Asia.

Can 6061 aluminum be die-cast?

Buyers familiar with wrought alloys like 6061 often ask if they can be die-cast. Technically, it is possible, but the results are usually poor due to hot-cracking and low fluidity. These alloys are better suited to extrusion or forging. Attempting to die-cast 6061 often leads to high rejection rates and costly tool wear, driving up the total cost of ownership. For die casting, buyers are better served by alloys such as A380 or AlSi10Mg.

What is the strongest aluminum alloy for die casting?

If the goal is maximum strength and wear resistance, A390 and AlSi10Mg are typically considered the strongest die cast alloys. A390 provides exceptional hardness, making it suitable for engine blocks and pump housings. AlSi10Mg, meanwhile, delivers high fatigue resistance, making it attractive for aerospace and EV applications. Buyers should note that both alloys are harder to machine and may increase tooling complexity, so they are best reserved for high-performance applications where strength justifies cost.

Is die cast aluminum rust proof?

Aluminum does not rust in the same way steel does, but it can corrode under certain conditions. Alloys with higher copper content, such as ADC12, are more susceptible to corrosion in humid or marine environments. By contrast, A360 and AlSi10Mg provide stronger natural corrosion resistance. Buyers sourcing for outdoor or marine use should either specify corrosion-resistant alloys or request protective coatings like anodizing or powder coating.

Can die cast aluminum be anodized?

Yes, but the results vary depending on the alloy. High-silicon alloys such as A380 and ADC12 can be anodized, but the finish may appear darker or less uniform compared with wrought alloys like 6061. For cosmetic applications requiring a bright anodized finish, alternative coatings such as powder coating or plating may deliver better results. Buyers should clarify surface finish expectations early to avoid costly rework.

Why is die casting more expensive than other processes?

Many buyers are surprised by the initial cost of die cast parts. The main driver is tooling investment: a hardened steel die may cost between $15,000 and $150,000 depending on part complexity. However, once the die is built, unit costs fall dramatically with higher production volumes. For projects above 10,000 units annually, die casting is often the most cost-efficient process. For prototypes or low-volume runs, gravity casting or CNC machining may be better alternatives.

In summary, the “best aluminum die cast alloys” depend on the balance between volume, environment, performance, and budget. A380 suits most general applications, A360 and AlSi10Mg excel in corrosive environments, while A390 is chosen for extreme strength and wear resistance. Understanding these trade-offs ensures that buyers avoid unnecessary costs while meeting performance targets.

Work with Yongzhu Casting

Selecting the right aluminum die cast alloy is only half of the equation; the other half is choosing a manufacturer that can reliably deliver the required quality. A well-equipped foundry not only understands the differences between A380, ADC12, A360, and AlSi10Mg, but also has the testing, tooling, and quality systems to ensure those alloys perform consistently in production.

At Yongzhu Casting, we support buyers through every step of alloy selection and production:

• Broad Alloy Capability – We regularly cast with A380, ADC12, AlSi9Cu3, and AlSi10Mg, covering the most common global standards for automotive, electronics, and industrial applications.
• Certified Quality Assurance – Every batch undergoes spectral analysis to confirm chemical composition, along with CMM measurement and salt-spray testing where required. This ensures full material traceability.
• Design for Manufacturing (DFM) Support – Our engineers provide 24-hour feedback on drawings, complete with mold flow simulations to recommend the most suitable alloy and process parameters before tooling begins.
• Cost and Delivery Transparency – We offer 7-day price locks to protect buyers from short-term cost fluctuations, and maintain low MOQs to support both pilot runs and full-scale production.

By combining technical expertise with buyer-focused services, Yongzhu Casting reduces the risks associated with alloy choice and helps procurement managers achieve both performance and cost targets.

For RFQs or feasibility studies, send us your drawings, and our team will recommend the best alloy and provide a detailed quotation within 24 hours.

Conclusion

Understanding the properties of aluminum die cast alloys is essential for making informed sourcing decisions. From the widely used A380 to specialized alloys like AlSi10Mg, each option offers trade-offs in strength, corrosion resistance, machinability, and cost.

For buyers, working with an experienced manufacturer is critical. At Yongzhu Casting, we provide:

• Detailed alloy selection support.
• Spectral analysis and composition reports.
• Cost-effective DFM suggestions.
• 7-day price lock for stable procurement.

This ensures that you not only choose the right alloy but also reduce your total cost of ownership (TCO) and avoid delays in product launch.