Aluminium die casting is a metal manufacturing process that uses molten aluminium to produce metal parts. The exceptional quality and consistency of aluminium makes it a great choice for the die casting process. In particular, aluminium is widely used in the automotive, aerospace, and military among other industries.
If you want to learn more about aluminium die casting then this article takes a deep dive into how it works, its pros and cons, and industrial applications.
Positives and Negatives of Using Die Cast Aluminium
Many industries successfully use aluminium die casting in their manufacturing processes due to its plethora of benefits. However, there are some minor drawbacks to aluminum die casting that aren’t apparent right away but most definitely exist.
So, is aluminum die casting the best method for your desired application? Explore the pros and cons below to make an assessment.
Positives
- Due to the recyclable nature of the metal alloy, Aluminium die casting is an eco-friendly choice.
- Aluminium is also a corrosion-resistant metal alloy due to its natural oxide layer, making it the preferred option for marine and outdoor applications.
- The smooth surface finish of the metal alloy after the casting process also ensures that it does not need to be sent for additional polishing or machining processes thereby reducing the overall cost of the process.
- Aluminium as a metal alloy is particularly lightweight but can carry heavy loads and withstand high stress despite its low weight. This characteristic renders aluminum the clear selection for manufacturing parts for industries that prioritize reducing weight above all other factors, such as the automotive and aerospace sectors.
- Aluminium die casting produces significant quantities of parts in a time crunch, which makes it ideal for time-sensitive manufacturing.
Negatives
- While aluminum can be molded into any desired shape, the initial tooling cost for creating the dies and molds for these complex shapes can be quite high.
- Although the metal alloy itself is recyclable, the greenhouse gas emissions and energy consumption from aluminum die casting can be harmful to the environment.
Overview of Aluminium Die Casting
Custom aluminum die casting involves three main steps. The first step involves designing the molds which is followed by melting the aluminum and then finally filling it into the mold.
We’ve condensed this entire process into a single step-by-step guide to help you understand how it works.
- The first step is creating a new steel mold based on the design requirements, or choosing an existing one for reuse.
- A release agent is applied to the mold’s surface to prevent it from sticking to the molten aluminum.
- Next, the aluminium is transferred to the furnace. The temperature in the furnace is monitored very closely as the metal alloy needs to be taken beyond its melting point and to the exact casting point, a point determined through years of aluminium die casting.
- Upon reaching the casting point, molten aluminum is injected into the die casting machine. This process is achieved using a hydraulic or mechanical press. The press makes sure that the molten aluminum fills the die cast completely, forming the complete shape in the mold with excellent dimensional accuracy.
- Once the molten aluminum has completely conformed to the mold, it is left to cool and solidify.
- The solidified aluminum is then ejected from the die using ejector pins and is ready for production.
If you wish to gain a more comprehensive understanding of the topic, we have an extensive guide available on the process of aluminum die casting which you can read.
Applications of Aluminium Pressure Die Casting in Various Industries
Die cast aluminum, owing to its robustness, lightness, and thin-walled structure, finds application in a diverse range of industries, including:
1) Automotive
The fast production rates and high strength-to-weight ratio of the process makes it a natural fit for creating parts used in automobiles. That’s because the central goal of the automobile industry is to create vehicles that can withstand heavy loads without sacrificing on speed.
2) Aerospace
The parts used for the construction of an aircraft should not weigh them down during flight. And lightweight but highly stable aluminium parts are just the right fit. Most aerospace manufacturers also use anodized aluminum to give the aircraft a lustrous exterior.
3) Military
Parts created for the military by nature need to be incredibly strong and durable but also lightweight which is exactly why custom aluminium die casting is used to create their weapons systems, aircraft, and vehicles.
4) Medical
Equipment used in the medical industry usually has strict dimensional and precision requirements, especially surgical instruments that require a very high degree of precision.
The process of aluminium die casting is well-suited for the consistent, rapid, and efficient production of such precise parts. Aluminum is also a biocompatible material, meaning it is safe for use directly on humans.
5) Electronics
Aluminium has good thermal conductivity, allowing for rapid heat transfer and dissipation, making it ideal for use in applications that require high heat transfer, such as heat sinks, enclosures, and housings for electronic devices that are widely used in the electronics industry.
Conclusion
Aluminum as a material is highly versatile, a good conductor of heat, strong and lightweight making it one of the most valuable metal alloys in the world.
The valuable material of aluminum is complemented perfectly by the high production capabilities and dimensional accuracy of the die casting process.
At Sunrise, we have 10 years of manufacturing expertise in providing customized and efficient aluminium die casting services to meet the specific needs of our clients. If you require further information about our services or a customized quote, please do not hesitate to contact us.