Aluminum alloys are the essential piece when it comes to aluminum die casting. It is a process that produces complex designs, shapes, and textured surfaces for different metal parts. Aluminum alloys are known for their stability. As a result, many industries find them beneficial and practical for making metal parts.
Aluminum Casting: The Process
Die casting is one of the methods for forming metal parts. Many companies use aluminum alloys to make complex parts. Die casting is one of the most suitable options for complex shapes, structures, and designs.
For the die casting process, China aluminum die casting companies heat aluminum alloys in block forms. When they are hot enough, they begin to melt. The molten liquids must be put into molds to form a suitable shape and design. The aluminum die-casting mold has a hole within a steel die.
Aluminum mold shapes will differ based on the design of the intended part. The cavity has two halves separated once the aluminum has solidified. Upon separation, the aluminum product within the mold is visible. The product is often a precise design and usually requires little to no other machining processes.
The process is helpful for repetitive production because the steel die does not deteriorate quickly.Aluminum casting is best suited for producing large amounts of aluminum parts.
Aluminum Alloys: Types
- A380
It is one of the most popular aluminum alloys. The remarkable qualities that make it suitable and popular for die-casting. Its best qualities include high heat and corrosion resistance, and it is also lightweight.
- A383
This alloy is also known as ADC12. The alloy is robust, and its high heat resistance means there’s little chance it will crack when exposed to high temperatures. The A383 is a common alternative to A380.
- B390
The B390 has some unique properties that make it beneficial for several applications. It is hard and durable due to its resistance to wear.
- A413
It’s a special alloy with many unique features and benefits. Its main benefit is its high-pressure tightness. The die-cast alloy has many uses across multiple industries.
- K-Alloy
It is also known as the A304. The alloy has many benefits, including being a time and money-saver. Its die-casting process eliminates the need for additional procedures such as painting and anodizing. The alloy also uniquely protects its die-cast metal parts from environmental damages that would otherwise inhibit their performance.
- A360
While it has its setbacks, the A360 has incredible features. It has superior strength when exposed to high temperatures and high corrosion resistance. The alloy also has excellent pressure tightness and fluidity.
Picking The Right Alloy For An Application
Aluminum has a unique advantage; metal parts can be custom designed. The basis depends on company preference and the alloy’s properties.
It means that an aluminum alloy will match the application in any project design for any industry or niche. Therefore, China aluminum die casting companies will make metal parts based on the required characteristics for the best results.
The best alloy for an application depends on many factors, including; the intended use of the product and the characteristics of the alloy. Here are a few that you should know of.
Corrosion Resistance: They typically never change unless they are alloyed.
Strength: These are known and appreciated alloys based on their tensile strength and yield.
Heat Treating: When alloys remain intact during die-casting, especially during extreme conditions. The reduced segregation means that it has better workability.
Formability: Sometimes an application requires a formable alloy, i.e., they can undergo deformation
Weldability: These alloys have unique features such as thermal conductivity and solidification shrinkage.
Machining: These alloys have a high bendability, which will be suitable for drilling. Such alloys are typically resistant to low temperatures.
A few other properties to look out for include the following;
- Weight
- Stiffness
- Recyclability
- Finishing traits
- Strength-to-weight ratio
- Operating temperatures
Die-Cast Surface Finishing: Best Options
The China aluminum die casting processes are mainly complete. However, there are some technical finishing procedures that the metal parts may need to undergo to be fully functional and aesthetically pleasing.
- Anodizing
It is one of the more affordable finishing options. The process makes the metal parts more resistant to corrosion and more durable. The finishing process involves creating a protective oxide layer with a chemical similar to ceramic to make it non-conductive.
Essentially, the finishing makes the aluminum anodized. It achieves this through the formation of an insulated layer. The finished part, therefore, ends up being non-conductive.
- Powder Coat
It is a popular finishing formats for aluminum casting. Some of the companies more likely to opt for this finishing option are industrial equipment manufacturers. Essentially the process uses an electrostatic process to apply dry powder. The curing procedure is challenging because it occurs at a high temperature.
This finishing process is advantageous because the cast parts end up being resistant to dings and scratches. Another benefit includes the various colors, glosses, and textures the metal parts get.
- Chem Film
It is also known as a conversion coating. It’s a popular choice that uses a chemical conversion coating where the surface of the die-cast aluminum goes through a chemical reaction. The reaction results in a transformation. The aluminum’s finished surface will then have a protective layer.
The result is that the surface becomes resistant to corrosion. It also protects it from loss of conductivity.
Conclusion
It is critical to understand the types of alloys that best suit your needs. Having an understanding of the unique properties of each of the alloys can also help when companies make their parts. Sunrise Metal is among the top aluminum die casting companies to get the best aluminum parts and productions for your manufacturing needs.