Aluminum Die Casting

With 15 sets of cold chamber die casting machines, we manufacture top quality aluminum die casting parts ranging weight from 30 gram to 10 KG

A Glance of Aluminum Die Casting Manufacturing

What is aluminum die casting?

image of die-casting-machine-cold

Aluminum die casting is the most popular cast process in the metal manufacturing industry. It’s widely used in the world.

Because aluminum has lower density and excellent mechanical strength, which can be manufactured with different shape easily. Meanwhile, aluminum part has good thermal and electrical conductivity. The using volume of aluminum is approaching or even exceeding steel.

 

Due to aluminum withstand a very high temperatures, which requires a cold chamber casting process that the raw material should be pre-melted and poured into the casting machine.

For many reasons, aluminum die casting has become the favored choice for buyers. Its characteristics and advantages can be summarized as below:

  • Light-weight and Durable
  • Withstand high temperature
  • Good Resistance to Corrosion
  • Excellent Thermal and Electrical Conductivity
  • Fully Recyclable if needed
  • Easy for Secondary Process

 Terminology of Aluminum Die Casting 

image of aluminum casting parts

  • Aluminum— A metal raw material, which is light weight and silver-colored that used for aluminum die casting process.
  • Gate – An extra flowing material that lead through injection runner and desired parts. After injection process is finished, the gate would be trimmed from parts by manual or machine.
  • Overflow – A small additional reservoir between product and runner system that used to avoid injection bubble and other die casting defects.
  • Draft – It’s also called draft angle that is designed to enable the desired casting parts to be easier fall off from mold cavity when ejection process.
  • Fillet– It’s a round feature existing casting parts that help ejection process, and improve parts strength as well.
  • Parting line– A small and light line left on casting parts, which happens the fitting area of mold core and cavity.( it looks like a flash line)
  • Boss– A protrusion feature existing on the casting parts that used for locating and fitting with other assembly components of a product.
  • Ribs– A thin wall feature existing on the casting parts that designed to enhance part strength.
  • Anodize— A surface treatment process that used to create a protective hard oxide surface on a casting product.
  • Cold Chamber Machine— A casting machine that pours the molten material from a furnace into the shot sleeve, instead of automatic injection mechanism that runs on a hot chamber casting machine.
  • Ejector— A mechanism device that equipped on casting mold, used to push the die casting part fall off.
  • Trim— The process of removing extra material from desired casting part, (like gates, overflows, flash).

The Aluminum Die Casting Process

Aluminum Die Casting MachineSince aluminum has very high melting point, which can not be directly injected with a hot chamber casting machine, so we must get the raw material pre-melted and pour it into a cold chamber machines to obtain aluminum die casting products.

A cold chamber casting process can be explained as five typical stages below:

 

 Step 1: Material Melting and Machine Adjustment

Prior to aluminum die casting, we need to get raw material melted and kept in a furnace that nearby a die casting machine. The first step is to adjust casting machine with slow shot condition that begins pushing air out of the sleeve and increase shot volume gradually to full fill the part cavity when injection process.

 Step 2: Mold Clamping

When we set up material, casting machine, and mold tool. It’s time to clamp the two cavities of mold tool together tightly, so as keep a closed loop when liquid aluminum come in. During the process, the interior of mold tool should be cleaned from the previous injection and then lubricated to facilitate the ejection of the next part.

 Step 3: Pouring

Since aluminum has a high molten point, we must melted solid aluminum into liquid aluminum with a furnace. And ladles a certain volume of molten aluminum from a prepared furnace, then pours it into a shot sleeve of cold die casting machine.

 Step 4: Solidification Phase

After liquid aluminum enters the mold cavity and consist the desired part as needed. Then the liquid material would cool down and solidify quickly under  water or oil cooling system of a casting mold. It enable to remove casting part naturally without deformation.

 Step 5: Part Removal and Trimming

It takes few seconds to solidify the injected part, and mold tool begin to open for two separated sides(core side and cavity side), the casting part would be ejected out from mold by ejection pins. After the part is fell off. The ejection pins extracted back to cavity side again for next around of casting.

After casting part is obtained, it’s a must to remove extra material from part by a machine or manual(runners, gates, overflows, and flash)

What is Aluminum Alloy?

 

Aluminum alloy is general term for aluminum-based alloys metal, which mainly includes copper, silicon, magnesium, zinc, manganese, nickel, iron, titanium, chromium and lithium. Aluminum alloy has low density, but high strength. It is similar or up to high-quality steel with good plasticity, it can be processed into various shapes, with excellent electrical conductivity, thermal conductivity and corrosion resistance.

Aluminum alloy is widely used in diverse industries.  Normally aluminum alloy can be divided into two categories: cast aluminum alloy, which is used in the as-cast state; and deformed aluminum alloy that can withstand pressure processing. It can be manufactured into aluminum alloy materials of various shapes and specifications. Mainly used for the production of automotive, home appliance, construction doors, and other industries.

 

The Difference of Aluminum Alloy and Zinc Alloy:

 

  1. The melting temperature of zinc alloy is about than 400 degrees, however the melting temperature of aluminum alloy is more than 700 degrees.

2, Because of different melting temperature, zinc casting process uses a hot chamber casting machine while aluminum casing using a cold chamber casting machine.  

  1. The overall hardness and tensile strength of zinc alloy is higher than aluminum(zinc 65-140, tensile strength 260-440, the hardness of aluminum alloy is 45-90, tensile strength 120-290)
  2. The manufacturing cost of zinc die casting is more expensive than aluminum die casting.

Common Aluminum Die Casting Material

 

A380(similar to ADC10) Aluminum Alloy

A380(similar to Japanese standard of ADC10) is the most wide use alloy for aluminum die casting material. It’s particularly used in automotive parts, electronic equipment, lighting industry. Compared to other material, A380 has excellent physical and mechanical properties for casting,  as it’s relatively light in weight, but with much better resistance at high temperatures and corrosion working condition.

On the other hand, A380 offers high electronic conductivity and stable dimension even for some complex part shape.

A383(similar to ADC10)Aluminum Alloy

A383(similar to Japanese standard ADC12) is another good aluminum die casting material, its properties are also similar to A380, but it might not function the same.  when in the high temperature working condition, A383 has higher strength with less chance of cracking under heat.(for example, like automotive engine, motorcycle engine…)

A360 Aluminum Alloy

Compared to A380, the A360 alloy offers higher strength at high temperatures, better ductility, and higher corrosion resistance. However A360 is much harder and difficult to cast, this is why people consider using A360 as not many as A380.

A360 is harder to cast than A380, which is why many die casters avoid it. However, it does offer higher strength at high temperatures, better ductility, and higher corrosion resistance, so you may want to consider this alloy depending on your casting abilities and needs.

A13 Aluminum Alloy

A13 offers excellent pressure tightness, its casting ability makes it intricate components. So it’s the first choice of automotive hydraulic and vessels parts.

Aluminum Alloy Mechanical and Physical Properties

 

Aluminum Alloy Properties

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