Aluminum die casting

What is Aluminum Die Casting?

Zinc Die Casting

Aluminum die casting is the most common process to produce aluminum casting parts, as aluminum is relatively easy to cast. It is widely used for many products. Aluminum alloy has excellent material flowability, highly corrosion resistant, and high dimensional stability with complex parts shape.

 

Meanwhile the aluminum die casting part could be lightweight, thin walls, and lower cost compared to zinc or magnesium die casting parts.

Aluminum die casting parts have very good physical properties that withstand high temperature. It’s widely used in automotive, airplane, medical, and other industrial products.

 

Aluminum die casting process requires to use cold chamber die casting machine with high pressure, during the aluminum die casting process, the raw aluminum material is molted in a furnace that set aside of die casting machine. Then the molted material is transferred from furnace to die casting machine by a ladle. After that, those material will be forced into the die casting mold cavity where the material is solidified to obtain desired die casting products.(A die casting mold tool can normally last for 800,000~150,000 shots)

Benefits of Aluminum Die Casting:

  • aluminum castingHigh dimensional stability for complex shapes
  • Closed to tolerance after a part is die-casted, as it only needs less machining process.
  • Very good strength and hardness properties
  • Good heat dissipating properties
  • High operating temperatures
  • Outstanding corrosion resistance
  • Could be thin wall and lightweight
  • Good stiffness and strength-to-weight ratio
  • Excellent EMI and RFI shielding properties
  • High thermal and electrical conductivity
  • Good finishing characteristics
  • Fully Recyclability
  • Non-magnetic

Aluminum Material Profile:

Density @ 293 K: 2.702 g/cm3
Melting Point: 660.37 °C – 933.52 °K
Boiling Point: 2467.0 °C – 2740.15 °K
Number of Protons/Electrons: 13
Number of Neutrons: 14
Crystal Structure: Cubic
Natural Color: Silvery or white

The Process of Aluminum Die Casting

Die casting machine, aluminum raw material, and die casting mold tool are the three basic factors to produce a die casting parts. For an aluminum die casting process, it particularly requires to use a cold chamber casting machine under a high pressure.

During the aluminum die casting process, the raw aluminum material is pre-molted in a furnace that set aside of die casting machine. Then the molted material is transferred from furnace to die casting machine by a moveable ladle. After that, those material will be forced into the die casting mold cavity where the material cools and solidifies to obtain desired die casting products. Here below are the process step breakdown.

 

Step 1. Material Melting

Since aluminum has a very high melting point(660.37 °C) that can’t be melted inside a die casting machine directly. This is why we need to pre-melted it with a furnace that attached with a die casting machine.

 

Step 2. Mold Tool Mounting and Clamping

It’s almost similar to injection molding, the die casting process also needs a mold tool for casting process. Therefore we need to mount the die casting mold tool on a cold die casting machine.

 

Step 3. Injection or Filling

The molten material is transferred from furnace to die casting machine by a moveable ladle. In this stage, the material will be poured and forced into the die casting mold cavity where the material cools and solidifies to obtain desired die casting products.

 

Step 4. Cool and Solidification

After the die casting mold tool is fully filled with molten material, it takes 10 ~50 seconds to cool and solidify( it depends on part structure and size).

 

Step 5. Part Ejection

When the mold opens, the casted parts would be ejected off by ejection pins from die casting mold tool. Then the raw casted parts is ready.

 

Our Aluminum Die Casting Service

Eco Die Casting company is one of the leading precision aluminum die castings manufacturers in China, We are dedicating to providing customers high quality casting products while keeping their cost with very economical manufacturing solution.

 

As our facilities were certificated with ISO 9001-2008 and TS16949 quality system, it enables us to provide clients high quality products in accordance with international quality standard, and ship the products to worldwide customers from our factory.

 

We are capable of producing both high quality die casting parts and die casting mold tools. Our main capabilities can be breakdown as below:

 

  • Aluminum alloy material we use: A356, A360, A380, A383 A413; ADC1, ADC3, ADC6, ADC10, ADC12;  ZL102, ZL104, AlSi12, YL104, YL112,  YL113
  • Secondary Process: CNC machining, drilling, tapping, assembly, etc
  • Surface Treatment: Electro-plating, powder coating, polishing, sand blasting, heat treatment, painting, anodizing, chrome plating are available
  • Die Casting Mold Material: H13, NAK55, NAK80, SDK61, S136, LKM2344, LKM718, etc
  • Mold Base Brand: LKM(China), DME, EMP, Hasco, MISUMI
  • Mold Life: 80,000~150,000 shots
  • Tolerance Standard: +/-0.005mm
  • Part Weight: 30 gram~15KG
  • Die Casting Machine Tonage: 120T~1650T
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