What is Aluminum Die Casting?
This process starts with melting aluminum alloys and injecting them into molds under high pressure.
The molten metal solidifies quickly, forming precise and complex parts.
At Yongzhu Casting, we excel in the production of custom aluminum parts, thanks to our machines and highly skilled technicians and sustainability management.
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To fully understand aluminum die casting is not something that can be summarized in a single article. Therefore, we try to mention the complete information here. In order for you to get the information you want to know directly, you can click on the picture below and we are ready to set up the jump.
Benefits of Aluminum Die Casting
1. Mass Production
Once a high-quality custom mold is created, large-scale production becomes highly feasible. This is due to the mold’s heat resistance and, most importantly, its reusability.
As a result, it’s relatively simple to replicate the same design multiple times using a single mold.
2. Quick Turnaround Time
It’s easy to assume that creating a complex aluminum die cast part would be time-consuming. However, the initial design phase is usually the longest part of the process.
Aluminum die casting is actually one of the fastest methods for manufacturing such products, especially with our advanced machinery.
3. Accommodates Intricate Designs
Regardless of how complex or detailed your design is, aluminum die casting allows for the production of precise, close-tolerance components.
This ensures that the final product will meet your exact design specifications.
4. Lightweight but Strong
Aluminum die casting provides the ability to manufacture lightweight components without sacrificing durability.
Whether your design involves thin walls or intricate features, the resulting product will be strong enough to withstand significant pressure or potential damage.
General Applications for Aluminum Die Casting
Aluminum die cast components are valued for their exceptional properties such as thermal conductivity, impact resistance, lightweight nature, and durability under high temperatures. These qualities make aluminum die casting a popular choice across various industries.
Due to the lightweight nature of aluminum alloys, they are extensively used in manufacturing numerous automotive parts. Examples include engine brackets, lighting components, engine compartment parts, car audio systems, seat belt components, and wiper parts.
Some automotive components produced using aluminum die casting are pistons, connecting rods, transmission housings, carburetor housings, steering gear housings, clutch housings, wheel hubs, valve covers, shade poles, stepper motors, heat sinks, alternator housings, forks, stators, and headlights. Additionally, for electric vehicles, die-cast aluminum is used in gearboxes, heat sinks, intake tubes, chassis, car rims, and engine cylinder heads.
In the energy sector, aluminum die casting is commonly used for parts that require both strength and heat resistance.
Typical applications include components for solar energy systems, wind turbines, energy storage systems, and battery housings. These parts are crucial for enhancing the efficiency and longevity of energy generation and storage systems.
Aluminum die casting is extensively used in the lighting industry due to its excellent heat dissipation properties and durability.
Applications include heat sinks, lighting enclosures, fixture housings, reflectors, and LED housing units. These components help improve lighting performance, especially in outdoor, industrial, and architectural lighting.
The medical field benefits from aluminum die casting because it allows for precise, lightweight, and durable components.
Some common applications include parts for medical equipment, such as pump housings, motor casings, MRI machine components, and surgical tool parts. These components ensure high performance while meeting the stringent regulatory standards of the medical industry.
Aluminum die casting is also used in the home furnishings sector for producing decorative and functional components.
Examples include furniture frames, handles, brackets, curtain rods, and door hardware. These parts are lightweight, stylish, and provide durability, making them suitable for modern home décor and construction.
In industrial machinery and equipment, aluminum die cast parts are critical due to their strength and ability to withstand high mechanical loads.
Common uses include motor housings, pump parts, gearbox components, cooling system parts, and various mounting brackets. These die-cast components help improve the durability and operational efficiency of industrial machines.
Aluminum Die Casting Process
Aluminium Die Casting Services
Step 1: Design (2-5 Days)
The first step is designing the mold based on your product’s requirements. During this phase, we collaborate with you to figure out the best solution. Several key factors are considered:
- The size of the die casting and how well it aligns with the mold
- Whether the mold’s design supports efficient die casting
- Your product’s future demand and production requirements
Step 2: Producing (5-45 Days)
Once the design is finalized, the production process begins. During this stage, the custom mold created in Step 1 is used to produce the aluminum die-cast parts.
Melting Aluminum:
High-quality aluminum alloys are melted in a furnace at temperatures typically ranging from 660°C to 750°C (1220°F to 1380°F).- Injection and Casting:
The molten aluminum is injected into the mold under high pressure, ensuring that the material fills every detail of the mold, even complex shapes. - Cooling and Ejection:
After the aluminum has been injected, it’s allowed to cool and solidify within the mold. Once the metal has cooled to the desired temperature, the cast part is ejected from the mold. Trimming and Finishing:
Any excess material, known as “flash,” is removed from the cast part. This trimming process is done either manually or using automated machinery, depending on the complexity and volume of production.Quality Inspection:
Each part undergoes a rigorous quality inspection to ensure it meets the design specifications.
Step 3: Shipping (5-30 Days)
The time required is different depending on the mode of transport. Air freight is fast, but more expensive, sea freight is cheaper, but takes longer, you can choose according to your situation
Cost Analysis
The cost of aluminum die-cast parts has many aspects, but the main ones are as follows
Material
We utilize aluminum alloy in our production process. The price of A380 alloy ranges between $1.3 and $1.4 per kilogram, while the cost of ADC12 is typically around $2 to $3 per kilogram.
The overall cost of aluminum alloys will vary depending on the volume of your order.
Casting Cost
Aluminum die casting tooling can range from $0.2 to $20. The exact cost of die casting will depend on the size and complexity of the parts you need.
Machining
CNC machining costs range from approximately $10 to $200 per hour.
Although CNC machining can seem costly, it provides excellent value for the precision and quality it offers.
Surface Treatment
Powder Coating: The average cost is about $1 per unit.
The final price is determined by the size of the part and the surface area that requires coating.
Materials for Aluminum Die Casting
Several aluminum alloys are suitable for die casting. Commonly used alloys include A380, 383, B390, A413, A360, ADC12, and CC401. At Yongzhucasting, we typically use the grades A380 and ADC12, but we can also accommodate other aluminum alloys to meet specific customer requirements.
- A380: A380 is one of the most widely used alloys for aluminum die casting due to its lightweight nature and excellent mechanical properties. It offers good strength even at elevated temperatures, excellent fluidity, pressure tightness, and resistance to hot cracking.
- A360: Although A360 offers superior strength at high temperatures, improved corrosion resistance, and better ductility, it is more difficult to cast, which is why many manufacturers prefer not to use it frequently.
- A383: This alloy is preferred for producing intricate parts where specific die-filling characteristics are required. It also maintains high strength at high temperatures and has a lower risk of cracking under heat stress.
- CC401: CC401 is another aluminum alloy utilized in die casting due to its balance of mechanical properties. It provides good strength and rigidity while maintaining excellent resistance to corrosion. This alloy is often used in components that require high performance under mechanical stress, such as aerospace parts, electrical components, and high-strength machinery.
- B390: B390 is a high-silicon-content aluminum alloy known for its excellent wear resistance and high hardness. It is typically used in applications where these properties are critical, such as in automotive engine blocks, pistons, and other high-stress components.
- ADC12: ADC12 is a widely used aluminum alloy in die casting, known for its excellent castability and fluidity. This alloy is popular for producing components that require good dimensional accuracy, such as engine blocks, cylinder heads, and automotive parts. It offers good resistance to corrosion and high strength, especially under heat, making it ideal for parts exposed to high operational temperatures.
- A413: A413 provides a balanced set of mechanical and physical properties. It resists cracking and offers good pressure tightness, making it an ideal choice for die-casting hydraulic cylinders.
The Various Grades of Aluminum for Die Casting
Aluminum die casting utilizes a range of different grades, including 1100, 6061, 3003, 5052, 2014, 2024, and more.
- 1100 Aluminum: This is the purest form of aluminum available. While it doesn’t harden like other metals, it offers excellent corrosion resistance, weldability, and high thermal conductivity. It can be formed into various shapes and products, though it is not suitable for heat treatment. Due to its ductility in the annealed state and corrosion resistance, 1100 aluminum is often used for products like cooking utensils.
- 3003 Aluminum: 3003 is essentially pure aluminum with the addition of manganese for improved strength. It is a cost-effective alloy suitable for most applications but is not designed to withstand high temperatures. It is commonly used in making cooking utensils and pot lids.
- 6061 Aluminum: This is one of the most commonly used alloys for extrusion processes. It offers high corrosion resistance, excellent welding properties, and strength, making it ideal for products exposed to wear and tear. 6061 Aluminum can handle high humidity environments and provides ultimate tensile strength of around 42,000 psi, with a yield strength of about 35,000 psi. Its elongation ranges from 8% to 10%, depending on the thickness. Although mold steel is slightly harder, 6061 is known for its flexibility under impact.
- 5052 Aluminum: 5052 aluminum is known for its high corrosion resistance, especially in marine environments. It also offers good formability, making it suitable for a range of applications, including marine parts, fuel tanks, and pressure vessels. 5052 has good weldability and can be used in environments where other alloys might suffer from corrosion. However, it is not designed for high-temperature applications.
- 2014 Aluminum: 2014 aluminum is an alloy typically used in aerospace and military applications due to its high strength and excellent machinability. It is not as corrosion-resistant as other aluminum grades, which is why it is often used with protective coatings. 2014 is preferred for structural applications that require toughness and strength, such as aircraft parts and heavy-duty machinery components.
- 2024 Aluminum: 2024 is one of the most popular aluminum alloys for aircraft structures due to its high strength-to-weight ratio. It is primarily composed of aluminum, copper, and magnesium, giving it excellent fatigue resistance and strength. Like 2014, it requires surface treatments for corrosion resistance, but its superior strength makes it ideal for critical aerospace components, including wing and fuselage structures.
What are the common alloys used in die casting?
Die casting commonly utilizes aluminum, copper, magnesium, silicon, zinc, tin, and lead alloys. Aluminum is the most frequently used due to its lightweight, corrosion resistance, and excellent castability.
What are the typical aluminum alloys used in die casting?
The most common alloys used in aluminum die casting include A380, A360, B390, A413, and ADC12. These alloys are chosen for their high strength, fluidity, and casting performance, making them ideal for industries like automotive, energy, and electronics.
Why is aluminum preferred in die casting over other metals?
Aluminum stands out because it’s lightweight, highly recyclable, and offers an excellent strength-to-weight ratio. Its corrosion resistance, high thermal and electrical conductivity, and ability to handle high temperatures make it a preferred choice in many industries, such as automotive and electronics.
What is the role of pressure in aluminum die casting?
Pressure plays a key role in ensuring that molten aluminum fills the mold completely, resulting in a high-quality casting with tight tolerances. The applied pressure can range up to 500 kg/cm², depending on the size and complexity of the part.
What are the benefits of aluminum die casting?
Aluminum die casting allows for high-volume production, excellent dimensional accuracy, and the ability to create complex parts with thin walls. The process is highly efficient, producing precise components with minimal secondary operations.
What is cold chamber die casting?
In cold chamber die casting, molten metal is ladled into a cold shot chamber, and a plunger forces it into the die. This process is ideal for high-melting-point metals like aluminum and results in parts with excellent surface finishes and tight tolerances.
What are the common surface treatments for aluminum die cast parts?
Surface treatments such as powder coating, anodizing, and chemical films are widely used to enhance durability, corrosion resistance, and aesthetics. Powder coating offers a robust finish, while anodizing provides a decorative, wear-resistant oxide layer.
How long does it take for an aluminum mold to wear out?
The lifespan of a die casting mold can vary based on the material, complexity of the design, and production volumes. Generally, a well-maintained mold can last for up to 1,000,000 cycles before requiring significant repairs or replacement.
Can I use aluminum alloys for high-temperature applications?
Yes, specific aluminum alloys like A360 and B390 are designed to maintain strength at elevated temperatures, making them suitable for high-heat environments like engine components and automotive parts.
What are the environmental benefits of aluminum die casting?
Aluminum die casting supports sustainability as aluminum is fully recyclable without losing its properties. The die casting process produces minimal waste, and scrap material can be reused efficiently, reducing environmental impact.
How does aluminum die casting compare to other manufacturing processes like sand casting?
Aluminum die casting provides better precision, higher production rates, and thinner walls than sand casting. It is particularly well-suited for high-volume production, while sand casting is typically used for lower-volume runs and larger, less intricate parts.
What factors influence the selection of an aluminum alloy for die casting?
The selection of an aluminum alloy depends on factors like the part’s required strength, heat resistance, corrosion resistance, and ductility. For example, A380 is widely used due to its balance of properties, while A360 is preferred for high-pressure and heat-sensitive applications.
What are some common defects in aluminum die casting?
Common defects in aluminum die casting include porosity, shrinkage, cold shuts, and cracks. These can be minimized by optimizing the casting process, including proper mold design, temperature control, and pressure application.
How can I ensure consistent quality in aluminum die casting?
Maintaining consistent quality in aluminum die casting involves precise control of the casting environment, including temperature, pressure, and cooling rates. Regular mold maintenance and proper alloy selection are also key factors in achieving high-quality results.
What is the difference between hot chamber and cold chamber die casting?
Hot chamber die casting involves melting the metal directly in the machine, suitable for lower melting-point metals like zinc and magnesium. Cold chamber die casting, used for aluminum, involves ladling molten metal into a cold chamber before injection into the die.
What is gravity die casting, and how does it differ from pressure die casting?
Gravity die casting, also known as permanent mold casting, uses gravity to fill the mold rather than high pressure. It is slower but suitable for lower-volume production of larger, less intricate parts. Pressure die casting is faster and preferred for high-volume production of complex components.
What factors affect the dimensional accuracy of aluminum die cast parts?
Dimensional accuracy in die casting is influenced by mold design, the cooling rate of the metal, and the pressure used during casting. Properly controlling these variables helps minimize warping, shrinkage, and other defects that can impact accuracy.
How does aluminum die casting help in reducing production costs?
Aluminum die casting reduces production costs by enabling the mass production of complex parts with minimal secondary machining. The high-speed process allows for rapid production, while the reuse of molds helps reduce material waste.
Can aluminum die casting be used for thin-walled parts?
Yes, aluminum die casting is ideal for producing thin-walled parts due to its ability to fill intricate molds under high pressure, creating strong, lightweight components that maintain their dimensional accuracy.
What are the benefits of using aluminum in the automotive industry?
Aluminum alloys are widely used in the automotive industry for their lightweight, high strength, and corrosion resistance. They help reduce the overall weight of vehicles, improving fuel efficiency and performance, while maintaining durability in high-temperature environments like engines and transmission systems.
Why Choose Yongzhu Casting
we have a range of 7 die casting machines spanning from 88 tons to 2000 tons. Each machine offers distinct capabilities based on its tonnage.
For instance, our 88-ton machine is well-suited for producing smaller parts weighing up to approximately 2 kilograms (4.4 pounds). On the other hand, our 2000-ton machine can handle much larger and heavier parts, typically up to approximately 50 kilograms (110 pounds) or more.
OUR EQUIPMENT
standalone melting furnace
We possess complementary melting furnaces for our die casting machines, yet we’ve also established a dedicated melting workshop for essential operational independence.
| Advantage | Description |
|---|---|
| Improved Product Quality | Melting metal separately allows for better control over alloy composition and melting parameters, leading to consistent quality and reduced defects. |
| Enhanced Production Efficiency | Continuous melting ensures a steady supply of molten metal to multiple die casting machines, minimizing downtime and maximizing overall production output. |
| Enhanced Safety | Separate melting area reduces the risk of accidents and contamination, providing a safer working environment for operators. |
The range of products we can manufacture includes, but is not limited to:
| Product Category | Examples |
|---|---|
| Small Automotive Components | Brackets, brackets, housings |
| Electrical and Electronic Enclosures and Components | Enclosures, circuit boards, connectors |
| Industrial Machinery Parts and Components | Gears, shafts, valves |
| Consumer Goods Components | Handles, knobs, fittings |
| Larger Structural Components for Various Applications | Automotive frames, aerospace components, beams |
| Product Category | Examples |
|---|---|
| Small Automotive Components | Brackets, brackets, housings |
| Electrical and Electronic Enclosures and Components | Enclosures, circuit boards, connectors |
| Industrial Machinery Parts and Components | Gears, shafts, valves |
| Consumer Goods Components | Handles, knobs, fittings |
| Larger Structural Components for Various Applications | Automotive frames, aerospace components, beams |
| Product Category | Examples |
|---|---|
| Small Automotive Components | Brackets, brackets, housings |
| Electrical and Electronic Enclosures and Components | Enclosures, circuit boards, connectors |
| Industrial Machinery Parts and Components | Gears, shafts, valves |
| Consumer Goods Components | Handles, knobs, fittings |
| Larger Structural Components for Various Applications | Automotive frames, aerospace components, beams |
Common Data
This table provides a general overview of commonly used aluminum alloy materials categorized under ASTM, EN, and GB/T standards.
It includes five aluminum alloy materials for each standard, highlighting their respective advantages and applications. Please note that this is just a general overview and does not cover all aluminum alloys available under these standards.
| Standard | Aluminum Alloy | Advantages and Applications |
|---|---|---|
| ASTM | Aluminum Alloy 6061 | High strength, good corrosion resistance, weldability. Used in structural components, aerospace, automotive parts, marine fittings. |
| Aluminum Alloy 7075 | High strength-to-weight ratio. Applications in aerospace, automotive, bicycle components, firearms production. | |
| Aluminum Alloy 5052 | Excellent corrosion resistance, suitable for marine applications, boat hulls, and shipbuilding. | |
| Aluminum Alloy 2024 | High strength and good fatigue resistance. Used in aerospace structures, aircraft components. | |
| Aluminum Alloy 6063 | Good extrudability. Applications in architectural and structural applications, window frames, door profiles. | |
| EN | EN AW-5083 | Excellent corrosion resistance, weldability. Commonly used in marine applications such as boat hulls, shipbuilding. |
| EN AW-6082 | High strength and good machinability. Applications in structural components, automotive parts, and machinery. | |
| EN AW-7075 | High strength alloy with good stress corrosion resistance. Utilized in aerospace, automotive, and marine applications. | |
| EN AW-2014 | Good machinability and mechanical properties. Used in aerospace, automotive, and sporting goods manufacturing. | |
| EN AW-5754 | Excellent weldability and corrosion resistance. Suitable for automotive, shipbuilding, and architectural applications. | |
| GB/T | GB/T 6061 | Similar to ASTM 6061, widely used in structural components, automotive parts, and bicycle frames. |
| GB/T 7075 | Comparable to ASTM 7075, utilized in aerospace, automotive, and sporting goods manufacturing. | |
| GB/T 5052 | Good corrosion resistance, suitable for marine applications, boat hulls, and shipbuilding. | |
| GB/T 2024 | High strength and good fatigue resistance. Used in aerospace structures, aircraft components. | |
| GB/T 6063 | Good extrudability. Applications in architectural and structural applications, window frames, door profiles. |
The industries involved in aluminum die casting
| Industry | Subdomain | Cast Components |
|---|---|---|
| Automotive | Engine Components | Pistons, Cylinder Heads, Crankshafts, Camshafts, Intake Manifolds |
| Chassis Parts | Brackets, Braces, Suspension Arms, Mounts, Hubs | |
| Electrical & Electronic | Enclosures | Junction Boxes, Control Panels, Terminal Boxes, Cabinets, Racks |
| Connectors | Electrical Connectors, Terminal Blocks, Plug Housings, Sockets, Pins | |
| Industrial Machinery | Power Transmission | Gears, Shafts, Couplings, Pulleys, Bearings |
| Pump Components | Impellers, Casings, Housings, Pump Bodies, Vanes | |
| Consumer Goods | Furniture Hardware | Handles, Knobs, Hinges, Drawer Slides, Caster Wheels |
| Appliance Components | Housings, Latches, Buttons, Dials, Panels | |
| Aerospace | Airframe Components | Wing Ribs, Fuselage Frames, Landing Gear Components, Fairings, Bulkheads |
| Engine Parts | Turbine Blades, Combustor Liners, Engine Housings, Compressor Blades, Vanes | |
| Home Appliances | Kitchen Appliances | Oven Racks, Burner Grates, Door Handles, Control Knobs, Grills |
| Laundry Appliances | Drum Assemblies, Door Hinges, Control Panels, Tub Rings, Dispensers | |
| Construction | Structural Components | Beams, Columns, Brackets, Trusses, Frames |
| Architectural Hardware | Door Handles, Hinges, Locks, Brackets, Handrails |
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