When metalwork companies design aluminum parts, it is essential to consider the suitable forming method for the durability of the products. Among all the other ways, aluminum die casting is the go-to solution for most manufacturers. Lightweight and low-density aluminum die casting is ideal for all shapes and designs with a thin wall section.
Therefore, the demand for aluminum die casting services is always high. However, it is also crucial to understand the types of alloys and processes used for the die casting process. So, let us know what die-cast aluminum is and what some of the most common types of die-casting alloys are.
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Die-cast aluminum is a molten liquid forced into the mold cavities under high pressure that immediately gets cold with a hardened shape, depending on the requirements. The die casting process involves a non-expendable mold to create metal castings for various industries. In addition, to enhance the corrosion resistance of aluminum, anodizing die-cast aluminum is used to increase hardness and provide better thermal insulation. An electrochemical process involves creating a layer on the metal surface called die-cast aluminum anodizing as a protective oxide layer.
BEST ALUMINUM DIE CASTING ALLOYS
Commonly include copper, silicon, iron, manganese, and zinc. Each of these components has a different impact on the properties of the design. Here are some of the most common die-cast aluminum alloys for various die-casting processes.
ALLOY A360
Aluminum alloy A360 offers excellent strength and corrosion resistance at fluctuating temperatures and weather. With perfect pressure tightness and flexibility, these are great but sometimes difficult to cast.
ALLOY A383
Alloy A383 has good mechanical properties and is used as an alternative to A380 aluminum alloy for various purposes.
ALUMINUM A380
The most common and comes with excellent properties, aluminum alloy A380 offers corrosion resistance, pressure tightness, fluidity, lightweight structure, excellent dimension stability, and more. This alloy is used in electronics, automotive, transmission, appliances, furniture, and more. Due to its high electrical conductivity and strength, a380 aluminum die-cast is the best alloy for die casting.
TYPES OF DIE CASTINGS & MOLDS
There are many ways die casting is done for metal product design. Two primary die casting processes are the hot chamber die casting process, and the cold chamber die casting process.
HOT CHAMBER DIE CASTING
One of the most common types of die casting is hot chamber casting, where a hot chamber is constantly in contact with the alloy, and liquified metal goes through a valve in the casting chamber. The piston helps press the melted metal at high speed, and quickly transfers the metal into a mold cavity. Hot chamber die casting is suitable for increased corrosion resistance for copper, magnesium, and zinc.
COLD CHAMBER DIE CASTING PROCESS
Cold chamber die casting includes pouring the melted metal into the injection system manually in the cold chamber. The chamber is filled with alloy and then passed through the channels to the casting mold. This casting type is ideal for metals like aluminum and copper with higher melting points.
MORE TYPES OF DIE CASTING
- Low Pressure Die Casting
- Vacuum Die Casting
- Squeeze Die Casting
- Semi-Solid Die Casting
ALUMINUM DIE CASTING MOLDS
While talking about the die casting process, die casting mold is an essential part of the process. It affects the final product and its characteristics. Hence, choosing a suitable mold for the die casting projects is vital. Aluminum die casting requires filling the mold with liquid metals to press and create any shape and size. The molds used in the process are essential.
Production Dies
Widely used for aluminum die casting, these are ideal for large-scale production. Made of durable metals to ensure higher accuracy and long life.
Trim Dies
Trim dies are the remaining trims off the runner liquid metal overflow and flash after a die casting process is done. Depending on the requirements, trim dies are used for trimming operations and design details. Therefore, custom aluminum die casting molds are high in demand due to different casting requirements. Most die casting processes start with producing the mold, where the cavity is created with machine steel molds. Other than this, here are some die-casting molds used in the process.
Unit Dies
For lower volume and small-sized casting, unit dies are low-cost production dies with a replaceable cavity. A die-cast unit holder keeps the unit die within the cavity intact. In simpler words, replaceable units can be removed from the main die without removing the standard frame from the machine.
Prototyping Dies
It fully features custom-made dies to make different parts as quickly as possible. These dies are used for creating prototypes. The process is almost similar to production dies. However, only the features are simplified to minimize the tooling cost.
Applications of Aluminum Die Casting
- Structural brackets
- Air/fuel delivery components
- Electrical connector
- Heat sinks
- Auto parts
Die Casting Products & Components
Talking about aluminum die casting and its applications, here is a list of components created from aluminum die casting.
Aluminium Die Casting Auto Parts
Top covers, assembly rear cover, extension arm, cable anchor bracket, oil pump housing, swing forks.
Die-cast Aluminum Cookware
All the non-stick die-cast cookware, pans, and more.
Die-cast Aluminum Heat Sink
Heat sinks for circuit boards, power lasers, fixtures, housing and LED, audio equipment, automotive equipment, communication equipment, and more.
Die Casting Mold Components
Here are some of the essential die casting mold components used in almost every die casting method for various applications
Molding Base System
Steel-plated frames and different parts allow mold installation in the casting machine.
Molding System
This includes a cavity, insert sliders, core, and insert pins. Cavity decides the shape when the moving center is closed.
Ejection System
As the name suggests, ejection parts are used to eject the pieces from the mold.
Overflow System
The overflow system channel eliminates air from the chamber. Overflow and venting slots are the main components to improve the casting shape.
Die Casting Manufacturers
If you are looking for some of the best-known pressure die casting manufacturers in Pune, here are a few names you can consider-
ZETWERK
A leading manufacturer and supplier of aluminum metalwork extruded parts and die casting materials to all the prominent locations worldwide.
Anandas Metal Industries
Pressure Die Casting (HPDC or LPDC), Plastic Injection Moulding, Plastic Compression Moulding, Tool, Die Manufacturers, Rubber Moulding.
Suniti Engineering Solution
Pressure Die Casting, Powder Coating & Machining
Abhi Engineering Works
Die Casting Dies, Pressure Die Castings, Gooseneck, and more.
Ibex Engineering
Aluminum gravity die casting manufacturer.