Your Ultimate Guide To Learn Die Cast Aluminum Alloy Properties

Die-cast aluminum alloys make ideal choices to cater to the needs of thriving industries like automotive and aerospace. Their unique properties come in handy in a multitude of high-impact applications. They are generally used for creating lighter parts and have more improved surface finishing options, making them so popular than other alloys.

Now, it is a must for you to know that each aluminum alloy exhibits unique features that make them fit for the die-cast process. In today’s post, we’ll discuss what are the properties of die-cast aluminum alloys, and how they can be used for different die casting purposes. Let’s get started!

Top Properties for Aluminum Alloys

It is Lightweight

Aluminum alloys are found to be relatively lightweight, with a density of around 2.67g/cm3. The light of die-cast aluminum helps reduce the overall weight of the vehicle. This, in turn, improves fuel efficiency.

It is a Good Conductor of Electricity

Die-cast aluminum effectively conducts electricity. It has a thermal conductivity of 120 W/mK. Therefore, it is helpful in applications that need heat dissipation, such as in the manufacturing of heat sinks.

Excellent Machinability

Excellent machinability is yet another promising property of aluminum alloys.

It can easily be machined using traditional techniques such as drilling and milling. Also, it works perfectly with more modern procedures such as CNC machining. The CNC machines are more effective for use since the aluminum has a more rigid surface due to the casting process.

Resists Corrosion

The ability to resist corrosion is another important property that makes aluminum alloys high in demand. This is because the thin layer of aluminum oxide (Al₂O₃) often forms on it when it is exposed to air. It protects the metal from reacting with the surrounding environment.

High Strength-to-Weight Ratio

Despite die-cast aluminum being lightweight, its strength-to-weight ratio is pretty high. It is generally strong and therefore fit for applications requiring strength.

Has a High Precision

Die-cast aluminum can easily be cast into complex shapes thanks to its high precision. It has a low melting point of about 660 degrees; hence it quickly melts, making it easy to cast into molds. Also, the fact that it has a high fluidity means that it can fill mold cavities rapidly. This gives more accurate and detailed parts.

Significant Electromagnetic interference and radio-frequency interference

This alloy has high electrical conductivity. Moreover, it has the ability to weaken electromagnetic waves. For this reason, both EMI as well as RFI shielding properties are increased. It is, therefore, a popular material for use in electrical components requiring shielding against interference from external sources.

A Compilation of the Top Elements Used to Form Die-Cast Aluminum Alloys

For an aluminum alloy to exhibit these properties and characteristics, it all starts with the elements used in creating it. Here are

the property elements that are preferably used to create the alloys:

• Aluminum – It’s a no-brainer that the foundation of a die-cast aluminum alloy is aluminum. It helps in making it lightweight and also has high strength
• Silicon – Silicone helps enhance the casting fluidity in the aluminum die-casting process. It has the highest level of commercial electrolytic aluminum of 0.01 to 0.15%. Silicon also helps reduce wear and tear in the property and reduces corrosion and shrinkage.
• Copper – Copper is known to be generally a strong metal, and it extends this strength to die-cast aluminum too. Also, it helps enhance the metal’s thermal and electrical conductivity. Only 2%-10% of copper is mixed during the process.
• Zinc – Mixing zinc in aluminum helps improve the alloy’s tensile properties. It also helps improve the casting fluidity as well as reduce its porosity.
• Magnesium– Adding magnesium increases the strength of aluminum. This also happens without decreasing its ductility.
• Iron – Among all other aluminum elements, iron is the most prevalent. It can easily dissolve at all molten stages of production due to its high solubility in molten aluminum.

Other elements added during the process include manganese, titanium, and nickel. All these elements combined help the die-cast aluminum achieve its properties of corrosion resistance, machinability, and better strength. The quantity used on each component varies depending on the desired properties required on the final product.

The table below highlights the chemical composition of various Aluminum casting alloys – this will help you make an informed decision:

Most Notable Industrial Applications of Aluminum Alloys

• Automotive Industry– As aforesaid, aluminum die-cast alloys are relatively light in weight. They, therefore, contribute to lower fuel consumption in the automotive industry.
• Handheld Devices– Aluminum alloy casting provides the RFI and EMI shielding effect in handheld devices like mobile phones. It also makes them more durable and rigid with minimal weight.
• Electronic Connectors– Aluminum has the Most Desirable electrical performance & shielding properties. It is therefore used for electronic connectors and housings even when the temperatures are high.

Aluminum Grades: Strategic Tips to Find the Optimal Alloy for Your Die Casting Needs

• A380 – A380 is a highly coveted die-casting aluminum alloy. It is preferred due to its sturdy mechanical and physical properties. Also, it’s lightweight, resists corrosion, and can withstand high temperatures.
• A383 – This grade has better resistance to hot cracking. It is commonly used where intricate components need precise characteristics of die filling.
• A360– A360 is highly flexible and boasts brilliant resistance to corrosion. In addition, it exhibits unmatchable strength even at higher temperatures.
• A356– A356 is lightweight, boasts top-notch mechanical properties, and is immensely weldable. Also, it has no hot cracking tendency and features a minor linear shrinkage.

To summarize, die-cast aluminum alloy has unique properties, increasing its use in big and small-sized industries. Different elements are combined to make the die-cast aluminum perform even better. In addition to this, specific alloy grades for die casting have multiple features that make them an ideal choice for various applications.

Sunrise Metal is a top-rated die-casting manufacturer with 10+ years of experience in the industry. We take pride in providing high-quality products in this sector and highly precise design tools to suit your needs. Talk to our industry specialists today to seek help for your next big project.