Most of us use aluminum components regularly, and countless methods have been used since inception to produce aluminum components. There are several methods for manufacturing aluminum components, of which aluminum die casting has been widely opted for.
Aluminum die casting is used in almost all industrial applications, from household to commercial ones. However, as much as it is popular for manufacturing standard parts, custom parts may also be manufactured according to the client’s specification; the such process is known as custom aluminum die casting.
Aluminum die casting is a process that has several steps, and after an extensive process, aluminum components are manufactured. However, the main concept of this kind of manufacturing is melting aluminum, pouring it into molds, and leaving it for solidification.
Since it is a detailed process, having an idea of how each step goes is very important to have custom aluminum die casting carried out. If you look forward to knowing more about it, read the article below. We have featured a detailed guide on manufacturing and working on the custom aluminum die-casting components used in different industries.
Why Choose Custom Aluminum Die Casting?
Before we get into the details of understanding how custom aluminum die cast works, it is a common thought that why opt for the die casting process when manufacturing aluminum components.
There are several methods, but when choosing the perfect one, nothing can beat aluminum die casting. It is a simple and durable method to go for. The best part is that it is suitable for producing large volumes of aluminum components; not only this but components with complex designs and dimensions may also be produced.
The output produced by the aluminum die-casting process is always up to the mark. It doesn’t need any added surface finishing and comes out very smoothly from the dies, known as molds.
It is a quick and steady process, and hence multiple components are produced at a breakneck speed using the aluminum die-casting technique.
What is the Working Mechanism of Custom Aluminum Die Casting?
Aluminum die casting might sound like a very straightforward process, but one of the critical components in the entire process is the die and its shape. If the shape of the die is perfect, the outcome will be up to the mark; if not, then the impact will be seen on the aluminum component produced.
Some working mechanisms involve in the process, and these are discussed below:
- Aluminum is taken in the form of alloys, and at a very high temperature, it is left to melt, and then once it has turned into molten form, it is ready to process further.
- The halves of two dies are first subjected to lubrication and cleaning to be clamped for further processing.
- Mold is needed as a die in which the aluminum is poured and left to settle. Hence steel cavities are primarily prepared in advance. Once it is ready, it can be used to manufacture aluminum components.
- This cavity is then filled with heated and melted aluminum, and the process of injecting the aluminum is carried out with high pressure.
- The pouring of aluminum also depends on the machine used for die casting, it could be either a hot chamber or a cold chamber, and the operational process for both varies a little.
- The die-casting process using a cold chamber involves hydraulic cylinders that help in pouring the molten metal into the dies.
- The hot casting is, however, created by pouring aluminum with an injecting tool. When the casting cools down, it removes the desired shape upon solidification.
- After the aluminum has solidified, the cavity is opened to remove the ready components.
- Any excess aluminum material present on the casting is cut down or trimmed to make the look finished.
Custom Aluminum Die Casting Features
The properties of aluminum have been quite ideal for making it suitable for manufacturing different products, and the most important aspect is its corrosion resistance. At the same time, it is strong enough to stay durable.
Moreover, when it comes to the die-casting process, the component’s surface is also finished and doesn’t require any post-processing unless it is created using a sand-cast mold. So, it is a versatile option to manufacture custom aluminum components widely used in many applications.
Tips on Creating Excellent Custom Aluminum Die Casting Components
The aluminum die-casting design needs some essential considerations which may uplift the design and eliminate the chance of flaws in the output. Some of these tips may comprise the following:
1.One of the most important things to consider for an aluminum component is the shape and size of the radii and filets. One thing is for sure these do depend on the application, but they must be at least 1mm.
To avoid stress concentrations, it is essential to ensure that the component has no sharp corners, and when areas with high load are needed, a larger radius must be used.
2.The design’s strength and stiffness also matter to assess the components’ wall thickness. The size and thickness of the component must also be assessed in the process of creating components.
However, the standard wall thickness in aluminum-based components must range between 1.016mm to 2.032mm.
3.In creating aluminum components using the die-casting process, many holes and windows are used so that the fluid may get some passage, or a connection could be created between the two parts. It must be ensured that these holes and windows do not negatively impact the strength of the final component.
The surface finishing process doesn’t exist in these components; however, some trimmings could be carried out through machining. This additional step must be taken into consideration when manufacturing components.
The fine details of the components are always matte, and any flaw on their part might even hinder their performance. The details of the design of the cavity have a significant role to play in the design of components too.
Sunrise Metal can be your go-to place to have all the aluminum components designed and manufactured, as we have many years of experience catering to multiple industries.
We consider your product and components’ importance and are open to all sorts of custom die-casting production, so contact us today for manufacturing aluminum components for your applications.