Manufacturing aluminum parts is essential, but this could be done using multiple production methods, and aluminum pressure die casting is a common process.
There are many advantages of choosing pressure die casting; it could also be used for multiple applications. However, the most important thing is understanding the main concept of aluminum pressure die casting and the related aspects so that you may make wise decisions regarding your aluminum components.
If you are in any industry looking forward to aluminum parts, you must go through this guide below, and you will learn many things about the process of aluminum die casting.
What is Aluminum Pressure Die Casting?
Die casting process helps manufacture affordable aluminum or other metal castings and is subject to manufacturing with a high speed and considerable pressure.
The aluminum pressure die-casting process is popular for manufacturing aluminum parts because it is reliable and suitable when identical parts with a high volume are needed.
In this process, the molten aluminum is poured into the dies with pressure through injecting technique, and it is an automated and very speedy process. Hence, the process is fast and ensures perfection when chosen for mass production.
The aluminum die casting is used for electronic, aerospace, hardware, and automobile applications.
Pros of Aluminum Pressure Die Casting
There are plenty of advantages that make aluminum die casting one of the most chosen options for manufacturing aluminum parts; some of these advantages are:
- The aluminum pressure die-casting process manufactures similar components with superior qualities; hence, industries that need the mass volume of the same components might benefit from it.
- This process can manufacture high-quality products with excellent accuracy, and the best part is that these are affordable due to mass production.
- The process is speedy. It doesn’t take too long for the molten form of aluminum to cool down.
- It can produce aluminum parts for multiple applications and go well with precise parts with complex geometries.
- The surface finish of the aluminum components manufactured out of the aluminum pressure die-casting process is also excellent.
- This process is also suitable for manufacturing aluminum casting with thin walls, ensuring lightweight parts are manufactured.
Crucial Considerations of Aluminum Die Casting
Aluminum die casting is one of the most traditional methods which is used to manufacture aluminum cast products; it requires some essential factors to consider, and these are discussed below:
Design of the Die
Design of the DieThe pressure die casting process for aluminum has some critical components; among them, the die is one of the essential components. The die will predict the design and layout of the actual component; hence, it must be perfect.
It is important to ensure that the die is always efficient and easy to use so that when you wish to remove it and attain the aluminum part, it gets easier for you to do the job. The parting line of the mold must be focused on while designing it.
Point of Injection
The molten aluminum is injected into the die, so it is crucial to identify the location of the injection point for each die; sometimes, there are multiple injection points as well. The need for multiple injection points arises when the risk of solidification of the aluminum lies.
The thickness of Componet’s Wall
The thickness of the component’s wall is another significant consideration to take seriously. There is a need to add consistency in all the similar parts regarding wall thickness. The technology doesn’t account for any minimum level of thickness, but the best components are the ones that have consistency in this aspect.
Post-Finishing Processes for Aluminum Components
Once the manufacturing of the aluminum parts is carried out using the pressure die casting process, the surface is most of the time finished and smooth. However, sometimes such components need an additional finishing on the surface, which could comprise the following options.
Anodizing
AnodizingThe die-cast aluminum can be anodized to make it resistant to corrosion and add durability. Anodizing is when a protective coating is applied to the aluminum parts.
Aluminum offers a high conductivity; however, the anodized layer added is non-conductive, and hence it helps with the electrical insulation of the aluminum component.
Such components may not be suitable for electronic applications because of the lack of conductivity added to them, and hence for electronic applications, other coating methods should be used.
Powder Coat
Another popular method used after aluminum die casting is powder coating. This process occurs at a higher temperature and is difficult to carry out. However, by adding a powder coat, the components become resistant to scratches, adding other textures in colors and a glossy finish.
Chem Film
The aluminum die casting can further be backed with a finishing method called chem film in which the components are subjected to a spray or a brushed process to apply the chem film. It helps with the electrical conductivity of the components.
Applications of Aluminum Die Casting
Aluminum parts manufactured using the aluminum pressure die-casting process are widely used in many industries, and some of the common applications are discussed below:
- In the construction industry, the window frames and structures of roofs are made using aluminum casting, usually created through the pressure die casting process. Moreover, the structure of bridges may also be created using the same process.
- The automobile industry must implement lightweight parts in such cases, and aluminum die-casted parts are the best option. Hence, the automobile industry highly depends on the aluminum pressure die-casting process.
- Electronic products, home appliances, and technology-oriented products like mobile phones comprise various aluminum components manufactured under aluminum die casting.
- Home and office furniture also use aluminum components because it is robust and, at the same time, very lightweight, which proves to be a better choice hence aluminum die casting is carried out to manufacture such parts.
- The aerospace industry needs such components which are durable, resist all kinds of impacts, and at the same time are lightweight, and nothing can beat aluminum in this case. Hence, the components for the aerospace industry are also manufactured using the aluminum pressure die-casting process.
Choosing the process for manufacturing an aluminum casting process is very important, but selecting the proper manufacturer is equally significant. Sunrise Metal offers good quality aluminum pressure die casting service, high-level finishing, and an affordable budget. So, contact us today and discuss your project to get the quote.