Aluminum components are all around us; almost every industry is now dependent on aluminum components forming to be a crucial part of their products. Several methods are used to manufacture aluminum components, and die casting is a widely used option.
Aluminum die casting is the most reliable method, which helps produce large volumes of components with high quality.
The aluminum die-casting process involves many details you must be aware of, and some of these important aspects will be learned in this article below.
If you look forward to learning more about the aluminum die-casting process and its related things, go through this article. So, let’s read below and learn about it.
What is Die Cast Process?
Aluminum die casting is a process in which molds manufacture the components. These molds give a layout and shape to the aluminum components. Die is the mold in which the molten aluminum is introduced and left to solidify, and once it has turned solid and cooled down, the die is removed, and the component is ready.
When it comes to die casting, three types of methods fall under this category. All these processes are discussed below:
High-Pressure Die Cast
High-Pressure Die CastAs the name suggests, the molds are filled with molten aluminum in the high-pressure die casting using a high-pressure injection technique. In this process, the mold is filled with molten aluminum, resulting in components that are excellently finished, have high mechanical properties, and are similar to one another.
Low-Pressure Die Cast
Low-pressure die casting is a process that is used to manufacture aluminum components, usually in the form of rotatory movement. In this process, the crucible adds molten aluminum to the dies. This process is suitable for manufacturing parts of aluminum material like car wheels.
Gravity Die Casting
The process of gravity die casting involves using dies that are either permanent or semi-permanent. The aluminum is heated, and then upon melting in the ladle, it is poured directly from that. In order to manufacture such aluminum components, which are of premium quality and are highly dense, they may be manufactured using gravity die casting.
Essential Things About Aluminum Die Cast Process You Must Know
The aluminum die-casting process involves multiple methods and techniques with some facts to consider and exciting things about this process that you must look into.
Finishing Touch
The aluminum components made out of die casting are of such a nature that no machining process is further needed on them. The die-casting process is so ideal that when a product solidifies and is removed from the die, it is finished and smooth on its surface.
However, if the aesthetic appeal of the finished components needs to be enhanced, then further decorative processes can be carried out to improve the appearance of the components.
Die casting can be Hot as well as Cold
This might sound surprising, but the die-casting process is hot and cold, and the two methods differ slightly. When you opt for hot die casting, the metal is first heated at a high temperature and then poured into the molds in a liquid state using high pressure.
Whereas, when you opt for cold die casting, it consists of using a high-temperature chamber and hence melts the metal in that.
The aluminum alloys are highly compatible with the method of cold die casting when compared to the technique of hot die casting. The life of the components is longer using the cold die casting process, and the functionality is improved using this methodology.
Variations in Aluminum Alloys
The kind of aluminum alloy chosen depends on the purpose or application of the component. However, when it comes to aluminum die Casting, the alloys that can be opted for in this process may include the ones A380, A360, B390, and CC401.
The attribute of every alloy is different when it comes to choosing a team for the process; for instance, they will have different levels of resistance against cracking, different mechanical properties, and different fluidity.
An example of the alloy B390 can be taken, which is common for using the engine blocks of automobiles because it offers a low level of ductility and is resistant to wear and tear.
Affordable Alternative Against Other Metals
Aluminum is high quality and can be attained for a lower price than other metals like iron and zinc. Especially when bulk components are needed to be manufactured, aluminum is a better choice.
Apart from being affordable, it is also light in weight and hence goes well with many applications that consider zinc or iron turn out to be heavy materials.
Suitable for Bulk Production
It is pretty common that industries wish to have a bulk quantity of aluminum components manufactured like aviation, automobiles, electronics, etc.
However, the die casting process is a perfect choice in this case because it offers rapid production, the dies are reusable, and hence in lesser time and cost-effectively a considerable quality of similar components can be manufactured.
Why Choose Aluminum Die Cast Process for Manufacturing Components?
Die casting is one of the highly opted processes for manufacturing aluminum components. However, many reasons make it suitable, and among them, its appropriate dimensional accuracy and excellent surface finish are among the most important aspects that make it suitable.
The process of die-casting is pretty straightforward, but still, adequate measures shall be taken when using this process of manufacturing components.
If any part of the die-casting technique has flaws, defects could also be observed in the final components. Hence, the die-casting process must be carried out with precise control of quality, and every step needs to be performed properly so that the final product is up to the mark.
At Sunrise Metal, you can find aluminum components manufactured using the die-casting process the way you want. We aim to cater your projects and products with high-quality components which are affordable as well as durable to go for. You can contact us today to discuss your requirements.