Why We Use High-Pressure Die Casting for Aluminum Parts
Over the past two decades, we’ve produced aluminum components using several casting methods. High-pressure die casting (HPDC), though, remains the go-to solution when precision, speed, and volume matter most. With injection pressures between 30–100 MPa and mold filling times under 0.1 seconds, this process gives us consistency at scale without compromising on tolerance or surface quality.
What Makes High-Pressure Die Casting Different?
Compared to sand or gravity casting, HPDC allows molten aluminum to enter the steel mold rapidly and solidify within seconds. This leads to fewer porosity issues, tighter tolerances, and a better finish—all with minimal machining.
Typical comparison:
| Feature | High-Pressure Die Casting | Sand Casting | Gravity Casting |
|---|---|---|---|
| Tolerance | ±0.05 mm | ±0.5 mm | ±0.2 mm |
| Surface Finish | Smooth, Ra 1.6–3.2 µm | Rough, Ra 6.3+ µm | Moderate, Ra 3.2–6.3 µm |
| Cycle Time | Seconds | Minutes to hours | Minutes |
| Ideal Quantity | 1,000+ pcs | Prototypes, low-run | Mid-volume |
Which Alloys Perform Best in HPDC?
We commonly use ADC12 and A380 for high-pressure die casting jobs. Both offer excellent flow characteristics and mechanical strength. For Russian clients, ADC12 is often the alloy of choice due to its availability and cost-efficiency.
- ADC12: Tensile strength ~310 MPa, elongation ~1.5%, excellent for thin-walled parts.
- A380: Slightly better at pressure tightness but more expensive.
What Types of Aluminum Parts Benefit Most?
High-pressure die casting suits parts where strength, dimensional accuracy, and surface appearance are critical. We’ve seen the biggest gains in:
- Automotive transmission housings
- Electronic enclosures
- LED lighting bases
- Pump and valve components
- Small appliance parts
Why It Matters for Buyers: Cost, Quality, and Lead Time
If you need thousands of units with consistent performance, HPDC offers a lower per-unit cost over time. Tooling is an investment upfront, but we’ve seen customers recover that cost within the first 5,000–10,000 pieces depending on complexity.
Key points:
- Lower unit cost for volumes above 3,000 pcs
- Less machining required (up to 60% reduction)
- Better surface finish means less post-processing
- Faster lead times due to short cycle time
What Are the Typical Lead Times?
Depending on mold complexity, we usually deliver first samples within 25–30 days. After approval, bulk runs take 10–15 days per 10,000 pcs. Urgent projects can be expedited with dual-cavity tools.
Quality We Guarantee in HPDC Projects
We back our parts with:
- Dimensional accuracy: ±0.05 mm
- Surface finish: Ra ≤ 3.2 µm
- X-ray inspection on pressure-tight parts
- Salt spray testing for corrosion-resistant coatings
All quality control steps are documented and traceable.
When Should You NOT Choose High-Pressure Die Casting?
HPDC isn’t right for every part. If the design has thick walls (>10 mm), internal cores, or low production quantity, we may recommend gravity or sand casting instead. Our engineers will always advise you on the best fit before quoting.
Final Thoughts for Buyers Looking at HPDC
We believe in making your project efficient—not just technically sound. High-pressure die casting is ideal if you’re scaling up and want consistent aluminum parts at competitive cost and timeline. We’ve helped customers in Russia and beyond shorten delivery times while improving product reliability.
For new inquiries or to request a quote, email us at yongzhucasting@gmail.com.
