Die Casting Service

What is Aluminum Alloy Die Casting

Aluminum alloy die casting is a manufacturing process that can produce geometrically complex metal parts using reusable die casting molds, called dies. The die casting process involves using a furnace, metal, die casting machine, and die.

Benefits of Aluminum Alloy Die Casting

Cost-effective
One of the primary advantages of aluminum alloy die casting is that it is a cost-effective method for manufacturing automotive parts. Compared to other manufacturing methods, aluminum alloy die casting requires fewer production steps, which reduces labor costs. Additionally, aluminum alloys are cheaper than other metals such as copper, brass, and steel, making it a more cost-effective material for die casting.

Lightweight
Aluminum is a lightweight metal, making it an ideal material for manufacturing automotive parts. The use of aluminum in automotive parts can help reduce the weight of the vehicle, which can result in better fuel efficiency and performance.

Strong and Durable
Aluminum alloys used in die casting are strong and durable, making them ideal for manufacturing automotive parts. Aluminum has a high strength-to-weight ratio, which means it is strong enough to withstand the stress of automotive use while still being lightweight. Additionally, aluminum is resistant to corrosion, making it a durable material that can withstand harsh environmental conditions.

Excellent Thermal Conductivity
Aluminum has excellent thermal conductivity, which means it can efficiently transfer heat away from the engine and other components. This makes it an ideal material for manufacturing automotive parts such as engine blocks, cylinder heads, and transmission housings.

Versatility
Aluminum alloy die casting offers a high degree of design flexibility, allowing manufacturers to create complex parts with intricate shapes and details. This versatility is essential in the automotive industry, where parts need to be designed to fit specific requirements and specifications.

Faster Production
Aluminum alloy die casting is a faster production method compared to other manufacturing methods such as sand casting or investment casting. The die casting process allows for high-volume production of parts, which can help manufacturers meet production deadlines and reduce lead times.

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Complete product range

CNC milling, CNC turning, aluminum die casting, magnesium die casting, zinc die casting, sheet metal fabrication, plastic injection, extrusion(contract), Heat sink(Thermal Solution)

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We prioritize delivering high-quality services, and our output is subjected to quality checks to ensure that our clients receive the best possible services.

Material of Aluminum Alloy Die Casting

AC 46100
AC 46100 is an aluminium alloy that’s widely used for die casting. It offers good weldability, strength, and hardness. This alloy also has excellent resistance to corrosion and wear, making it a good choice for applications that require these properties.
However, AC 46100 is not suited for applications that require high temperatures as it has a lower melting point.

AC 46500
AC 46500 aluminium alloy is a high-strength aluminium alloy mainly used to produce die cast parts. Its properties include high ductility, good corrosion resistance, and a high strength-to-weight ratio.
Typical AC 46500 aluminium alloy applications include automotive parts, electrical components, and industrial machinery. It is also often used in aerospace due to its high strength and corrosion resistance.

ADC 12
ADC 12 offers good weldability and corrosion resistance in die cast parts. It also has a higher melting point than AC 46100, making it a better choice for high-temperature applications. However, this alloy is not as strong as AC 46100 and is more expensive.

ADC 10
ADC 10 is the most commonly used aluminium alloy for die casting precisely machined parts. ADC 10 die cast parts possess high durability, strength, and versatility. This grade is also popular due to its anti-soldering properties and excellent machinability. Automotive, sports equipment, electronics, toys, printer parts, and instruments are some of the most common applications of ADC 10.

A380
A380 aluminium alloy offers high strength and ductility, making it an ideal choice for various applications. It also has excellent resistance to corrosion and wears, making it a good choice for die castings that will be exposed to harsh conditions.
In addition, A380 is easy to machine and can be welded and repaired. Some of the most common uses for A380 aluminium alloy include engine blocks, transmission cases, and structural components.

A360
This aluminium grade is generally used for parts that require excellent fluidity and pressure tightness. Products manufactured using A360 aluminium alloy possess high tensile strength and corrosion resistance even at high temperatures. This grade is more ductile than most aluminium alloys and is mainly used to manufacture parts for high-impact applications.

Al-Si8Cu3
Al-Si8Cu3 aluminium alloy is a high-strength, corrosion-resistant material that is often used to produce die-cast parts for the aerospace industry. It has a low density and high strength-to-weight ratio. Al-Si8Cu3 also has excellent resistance to fatigue and crack growth. In addition, the alloy’s low thermal expansion coefficient makes it ideal for use in high-temperature applications.

Al-Si11Cu3
The composition of Al-Si11Cu3 is aluminum (Al) – 90.5%, silicon (Si) – 10.0%, copper (Cu) – 3.0%. With a tensile strength of 310 MPa and a melting point of 577°C, it offers good castability and is easy to machine. Al-Si11Cu3 is used in the automotive industry for wheels and other parts that require high strength and good corrosion resistance. It is also used in the electrical and electronics industries for connectors and other parts that need good electrical conductivity.

Applications Of Aluminum Alloy Die Casting

Automotive industry
In the automotive industry, aluminum alloy die casting is ideal to use due to its properties like durability and lightweight alternative to steel and iron. Moreover, its lightweight feature makes it an excellent choice for transportable applications.

Renewable energy
In some parts, aluminum alloy die casting is used for power generation and distribution equipment in the renewable energy industry. The process of aluminum alloy die casting is used.

Aerospace
In the aerospace industry, aircraft demand components that can offer up-to-the-mark performance. Aluminum alloy die castings are excellent for aircraft as they are lightweight, highly durable, and affordable as they can withstand harsh operating and environmental conditions and have better fuel efficiency.

Agriculture sector
Aluminum alloy die castings can be utilized in several machines like combine harvesters or tractors in the agricultural industry. It is the best for use in these demanding applications as it offers durability and reliability.

Recreational vehicle
The aluminum alloy die casting process helps create many recreational equipment and vehicle parts in the recreational equipment industry. For instance, structural and functional components like axles, chassis, counter mounts, etc., and cosmetic components like hood ornaments.

Military/defense
Die casting helps produce parts for law enforcement, commercial, and military pieces in the military/defense industry. For example, it is used in making remington receivers, trigger guards, and many other parts for shotguns and rifles.

Industrial equipment
Aluminum alloy die castings are also used for multiple components of equipment and systems in the industrial machinery & equipment industry. For instance, die-cast equipment components cover connecting rods, bearings, and pistons.

Medical industry
Die-cast aluminum parts can be seen used in various devices and systems used in the medical industry. From diagnostic and treatment equipment to beds and surgical instruments, such productions are integrated into almost everything.

Consumer products industry
Aluminum alloy die castings are used in the consumer products industry. The elements help ensure the final products are robust as well as lightweight.

The Forming Principle Of Aluminum Alloy Die CastingThe Forming Principle Of Aluminum Alloy Die Casting

Aluminum alloy die castings must be formed by molds and combined with die-casting machines and aluminum alloys for comprehensive use. The principle of pressure die casting process is that the metal liquid is poured into the cavity of a precision metal mold at high speed under high pressure, and then the metal liquid is cooled and solidified into a casting under pressure. Cold and hot chamber die castings are two basic ways of die-casting process. In cold chamber die-casting, metal liquid is poured into the chamber by manual or automatic casting device, then the injection punch moves forward and presses the liquid metal into the cavity. In the hot chamber die casting process, the pressure chamber is perpendicular to the crucible, and the molten metal flows into the pressure chamber automatically through the feed port on the chamber. The injection punch moves downward to push the molten metal into the cavity through the gooseneck tube. After the molten metal is solidified, the die-casting mold is opened and the casting is taken out to complete the entire die-casting forming process.

In the process of making aluminum alloy die castings, the surface processing quality of the mold cavity can be effectively improved. And the surface of the mold cavity should not have obvious deep machining marks to prevent the mold from cracking due to stress concentration during work. When the mold is finished, the surface of the cavity should be effectively polished and ground to keep the surface roughness of the cavity under 0.8μm.

What Are the Two Types of Aluminum Alloy Die Casting?

Cold-Chamber Die Casting

Cold-chamber die casting involves introducing molten metal at room temperature into a separate shot chamber using a ladle or pouring method. The shot chamber contains a ram that vertically forces the molten metal into a steel mold (die) with movable and fixed sections. The ram applies pressure ranging from 2,000 to 20,000 PSI to propel the molten metal into the die. The pressure is maintained until the metal cools and solidifies, after which the finished product is ejected from the die. This method is suitable for high-melting-temperature alloys like aluminum.

Hot-Chamber Die Casting

Hot-chamber die casting is a metal casting process specifically designed for low-melting-point alloys like zinc, tin, lead, and magnesium. This process is the most common and faster method than cold-chamber die casting. In this method, the metal is melted within the casting machine, in a furnace connected to the machine. A hydraulic system injects molten metal into the die under high pressure. This process is efficient for producing intricate shapes with high-quality materials that have lower melting points. Still, it is not suitable for alloys with higher melting points due to the risk of damaging the pump that injects the molten metal.

Our Factory

Dongguan PowerWinx Metal Industries Co.,Ltd is a leading industrial manufacturer and service-oriented organization, specializing in precision metal, plastic and assemblies. We manufacture products from individual components to complete assemblies. Our capabilities include: Design & Tooling Fabrication Die Casting & Extrusion CNC Machining CNC Lathes Sheet Metal Fabrication Plastic Injection Thermal Solution and Assemblies Prototype We partner with OEM companies helping them optimize their cost of manufacturing using our engineering and manufacturing services. Our customer includes in the following industries: Medical Semiconductor Automation Telecommunications Renewable Energy Industries Application

We are dedicated to building solid partnerships and providing flexible solutions to enable our customers' success. We are adaptive and agile and help customers anticipate and prepare for unexpected changes.
Our talented global team is dedicated to delivering end-to-end product lifecycle solutions at the lowest total cost of ownership – enabling our customers to keep their commitments and stand out in their markets.
Our expertise is in design and engineering, components manufacturing and supply chain management services. Our suite of solutions spans the entire product lifecycle – from design, Manufacturing Processes, through to delivery. By understanding the unique complexity of each customer's business, we develop customized solutions that drive product innovation, cost savings, supply chain efficiencies and improved time-to-market.

We offer our customers an extremely efficient global network including 6 strategically located specialized centers of excellence focused on meeting our customers' needs. This strategic network provides our customers with the flexibility they need to respond quickly to changes in end-market demand. Our customer portfolio spans the enterprise, communications, consumer, aerospace, industrial, alternative energy and healthcare end-markets.

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Asked Questions

Q: Why is it called aluminum alloy die casting?

A: Aluminum alloy die casting is named for using dies – steel molds crafted primarily through cnc machining. These dies, consisting of a fixed, stationary half attached to the casting machine and a movable ejector half, serve as the molds into which liquid metal is injected.

Q: What is the difference between mold and aluminum alloy die casting?

A: Aluminum alloy die casting and permanent-mold casting are two key methods in metal part production. Aluminum alloy die casting injects molten metal into a steel mold under high pressure, ideal for small to medium-sized parts like those made of zinc, aluminum, and magnesium. It offers high precision, complex shapes, and efficient production rates. On the other hand, permanent mold casting pours molten metal into a reusable mold, typically made of steel or cast iron, suitable for larger parts composed of alloys like brass, bronze, and iron. Permanent mold casting is cost-effective, supports a variety of materials, and produces parts with high strength and good surface finish. The choice between the two depends on factors such as part size, complexity, and material properties.

Q: Is aluminum alloy die casting a precision casting process?

A: Yes, aluminum alloy die casting is generally considered to be precision casting.

Q: Is post-machining always required after aluminum alloy die casting?

A: Aside from trimming or deburring operations, post-machining your parts is not necessarily required after aluminum alloy die casting. Post-die-casting machining may be required for the final part if tight tolerances or specialized surface finishes are required, etc.

Q: What is the difference between forging and aluminum alloy die casting?

A: Casting involves heating metal in a furnace until it reaches a molten state. In this liquid form, the metal is poured into a die or mold to take on the desired component shape upon solidification. On the other hand, forging utilizes a combination of thermal and mechanical energy applied to ingots, causing the alloy to change shape while remaining in a malleable but solid state. Casting relies on transforming metal from liquid to solid within a mold. At the same time, forging achieves shape alteration by applying heat and force to a solid metal form.

Q: What are the parameters for aluminum alloy die casting?

A: The process parameters include heat treatment temperature and time. The heat treatment temperature of aluminum alloy die castings depends on the porosity rate of the die casting, and the holding time depends on the grain size and solid solubility, and segregation of each composition in the alloy.

Q: What is the best aluminum alloy for die casting?

A: Alloy A380 (ANSI/AA A380. 0) is by far the most widely cast of the aluminum alloy die casting alloys, offering the best combination of material properties and ease of production. It may be specified for most product applications.

Q: What is the minimum thickness for aluminum alloy die casting?

A: In most cases, the required minimum wall thickness for aluminum alloy die casting is as follows: 5 mm or 0.020 in for small castings. 0 mm or 0.040 in for medium-sized castings. 0 mm or 0.080 in for large castings.

Q: What is the draft angle for aluminum alloy die casting?

A: The typical draft angle for an aluminum alloy die casting part is two degrees per side. The calculation for that is simple if a person is familiar with die casting production part design, but is not familiar to most people.

Q: What temperature is aluminum alloy die casting?

A: Aluminium alloys die-casting dies should be preheated to approximately 240 to 300 oC. Experiences have shown that by increasing the die operating temperature from 205 to 315 oC, die production may be doubled (see Figure 2).

Q: What is the process of die casting aluminum alloy?

A: Aluminum alloys for die casting are melted in a furnace and then injected into the dies by the die casting machine. Once the liquid aluminum is injected into the dies, it rapidly cools and solidifies into the final cast part.

Q: What is the best aluminum alloy for die casting?

A: Alloy A380 (ANSI/AA A380. 0) is by far the most widely cast of the aluminum die casting alloys, offering the best combination of material properties and ease of production. It may be specified for most product applications.

Q: What grade of aluminum is used for die-cast?

A: This is the most commonly used and popular Aluminum alloy for die casting. It is preferred because of its strong mechanical and physical properties required for die casting.

Q: What is the best temperature for aluminum alloy die casting?

A: For aluminum alloys, the optimum pouring temperature range is 700°C to 750°C. At temperatures higher than this range, the casting results in large crystals, low strength and gases are entrapped in the castings, leading to defects known as blowholes.

Q: Can 6061 aluminum be die cast?

A: Highly engineered aluminum alloy 6061 gravity die castings are found in approximately 90 percent of durable goods, including all types of equipment and machinery, cars, trucks, trains, tools, appliances, wind turbines, defense products, weapons, medical products, nuclear plants, hydrants, pipes, oil wells, aircraft and ...

Q: What is the die casting tolerance of aluminum?

A: The aluminum die-casting tolerance for parting lines is also vital to consider. However, the permissible deviation is about +/-0.25mm which is equal to +/-0.01 inches.

Q: What is the shrinkage allowance in aluminum alloy die casting?

A: As the molten metal starts to cool down from melting temperature to room temperature, the cast will shrink towards its center. Castings commonly shrink between 0.4-0.6% of their volume, which can help the product to be ejected from the external walls of the die.

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