Metal enclosures are used widely in many industrial applications, primarily where equipment is either very expensive or sensitive.
This enclosure protects the equipment from all kinds of contaminations, dust, dirt, and the reaction of any fluids entering them. Hence productivity is maintained, and downtime is prevented.
These enclosures also allow heat dissipation, enabling the equipment to work perfectly in high temperatures.
These metal enclosures can be used for drilling equipment, batteries, electrical systems, etc. There could be multiple kinds of metal enclosures. However, the most commonly used is cast aluminum enclosure.
Cast aluminum enclosures can be manufactured using different processes, the common ones being die-cast or extruded aluminum enclosures. The two methods have pros and cons and are suitable for different applications.
If you are deciding which cast aluminum enclosure type will suit you, you must read this guide below. Here you will find detailed insight into both the methods and where to use them; let’s read below:
What is an Aluminum Enclosure?
Aluminum enclosures are durable and robust enclosures with a lower level of conductivity, and they offer resistance against a magnetic force which is quite good; this enclosure helps sheilding against the interference of different frequencies like radio frequency or electromagnetic frequency.
These enclosures are suitable to protect, store, and transport sensitive equipment and also for such applications that are subjected to extreme temperatures and highly corrosive environments.
Diecast Aluminum Enclosures
Casing aluminum comprises die casting as one of the most popular methods for producing aluminum casting products. The method consists of adding molten aluminum in the molds, called die, and upon solidification, the aluminum metal takes the shape of the mold.
Applications of Diecast Aluminum Enclosures
Aluminum has plenty of such characteristics that make it suitable for many applications, and hence it is well for the high-pressure die-casting process. When mixed with some other metals, aluminum helps improve its capabilities, and it ends up manufacturing numerous products suitable for use indoors and outdoors.
The die-cast aluminum products also cater to cast aluminum enclosures. These enclosures are suitable for use in cases for meters and switchboards and hence become suitable for handling the industrial environment.
Many healthcare equipment are also enclosed in diecast enclosures made of aluminum because they shield against radio and electromagnetic frequencies.
Pros of Diecast Aluminum Enclosures
Aluminum die casting is chosen for such enclosures, which require a complex geometry. Moreover, die casting is a kind of aluminum casting process that results in thinner textures; for instance, the walls of the enclosure are thin unlike extrusion which ends up with thick walls.
Hence, the thinner walls of the enclosure offer a lightweight solution, and at the same time, the die-casting process is known for its exceptional surface finishing, which needs no further processing.
Cons of Diecast Aluminum Enclosures
Although diecast aluminum enclosures gain significance in many sectors due to their corrosion-resistant properties, on the other hand, some problems might cause a problem in selecting this procedure.
The die-casting process is an experienced one, and hence it is unsuitable for low-volume production because the enclosure will cost a lot this way. On the other hand, one of the problems is porosity. The air traps inside the metal die, causing the texture to get a little porous.
Extruded Aluminum Enclosures
Extrusion is a process in which the aluminum is subjected to pass through a die using a hydraulic arm carried out by force. The excessive remaining part left after aluminum is shaped can be cut or subjected to a machining process.
Applications of Extruded Aluminum Enclosures
Extruded aluminum enclosures are suitable for indoor and outdoor use because they can withstand water and dust. These enclosures are primarily found in sensors, medical equipment, PCBs, and data systems.
Pros of Extruded Aluminum Enclosures
Aluminum enclosures made using the extrusion process are sufficient enough to deal with harsh environmental conditions; hence, they provide waterproof gaskets and EMI protection as well.
The installation process is also quick with aluminum enclosures, especially when installing PCBs, because it just has to slide the PCB to allow it to get into place. It offers excellent heat dissipation and hence protects the equipment from higher temperatures.
Cons of Extruded Aluminum Enclosures
There are some downsides of the aluminum enclosures made using the extrusion process, and the first one is that it can produce only some limited shapes and has some assembly constraints. Moreover, the caps of the aluminum enclosures are to be produced separately.
Which Process to Choose for Aluminum Enclosures?
As you have gone through detailed insight into both processes, selecting one among them would have become more accessible. Aluminum enclosures are, on their own, a very safe choice, irrespective of the manufacturing method. Since the material itself has such exceptional properties as corrosion resistance, durability, strength, etc.
However, when one of the processes has to be chosen among two options, you need enclosures in high volume, and the design requires high precision. In that case, it is suggested to opt for diecast aluminum.
On the other hand, when you need to install an enclosure in a challenging environment and your enclosure will be bound to handle high temperatures, and you want this at a low cost, then opting for an aluminum extrusion enclosure proves to be a better choice.
The enclosures made out of both processes are strong enough, but when compared, the extrusion process offers highly robust enclosures made with aluminum.
Choosing the right process to cater to your enclosure application is imperative because these are usually manufactured in bulk and hence need a high investment, so it is important to choose the process wisely.
Moreover, as much as it is important to choose the right process, choosing the right manufacturer is also important. Sunrise Metal is a one-stop solution for aluminum die-cast and the extrusion process. We have an experience of more than a decade, and we ensure to provide you with quality aluminum products that meet your project requirements.