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:
Since 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:
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.
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.
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.
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.
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)
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.
2, Because of different melting temperature, zinc casting process uses a hot chamber casting machine while aluminum casing using a cold chamber casting machine.
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 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…)
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 offers excellent pressure tightness, its casting ability makes it intricate components. So it’s the first choice of automotive hydraulic and vessels parts.