aluminum die casting factory-Sunrise Metal

ALUMINUM DIE CASTING PRODUCTION

The high pressure die casting process best illustrates our level of manufacturing capability during the whole process. We dedicate to provide high precision, low to medium volume for our customers who are struggling with small demand and limit of seeking for right suppliers.

CHOOSE SUNRISE METAL AS YOUR ALUMINUM DIE CASTING MANUFACTURER IN CHINA.

OUR PROTOTYPING ADVANTAGE
Strong R&D capability and rich engineering experience enable us

a. Design Mechanical parts b. Design For Manufacturing c. Cost saving suggestions d. PPAP capability

One-stop Solution

Integrating Rapid Prototyping, Tooling, Die casting, Machining, Assembling in house and Surface
Treatments, together with various value-added services.

Fast delivery:

a. Rapid Prototyping: 1-2 weeks for Volume less than 200pcs b. Rapid tooling: 2-4 weeks for production tooling,etc… c. Rapid Production: With Rapid tooling and quick production arrangement, we can provide quick production delivery.

Good at high mix, low to medium volume projects

Sunrise Metal focus on High Mix, Small to Medium batch productions. Our typical production order quantity is from 100 to 5000 parts.

EQUIPMENT
NO. Die Casting Shop Brand Ton Unit
1 Aluminum LK 280T 2
2 Aluminum LK 400T 2
3 Aluminum LK 500T 1
4 Aluminum LK 800T 1
5 Aluminum LK 160T 1
6 Aluminum Toshiba 250T 1
7 Aluminum Toshiba 350T 1
8 Zinc LK 38T 1
9 Zinc LK 88T 1

GALLERY
ALUMINUM DIE CASTING PRODUCTION SAMPLE
DIE CASTING TOOLING QUALITY
X-ray equipment for die casting parts-Lab measurement
X-RAY Detector
Carl Zeiss CMM--Lab measurement
ZEISS CMM
Quality Lab-Sunrise Metal
Spectrum Meter
REQUEST A QUOTE

If you got any questions, please do not hesitate to send us a message. We reply within 24 hours.

ALUMINUM DIE CASTING: THE DEFINITIVE FAQ GUIDE

Aluminum Die Casting is a process of casting Aluminum characterized by forcing molten Aluminum under high-pressure into the dies cavity. he tooling cavity is manufactured using two solid mold steel dies, which have been machined into shape, and Aluminum Die Casting works in the same way as an injection process.

 

WHAT DOES ALUMINUM DIE CASTING MEAN?

 

Casting a metal means shaping it by melting and then pouring it into a mold, As the metal cools and stabilized, it adopts the shape of the mold surrounding it, and once it’s wholly preserved, then got withdrawn. When you want to make cast aluminum products, manufacturers got to choose from several methods, and one of them called Aluminum Die Casting.

 

WHAT ARE THE QUALITY BENEFITS OF ALUMINUM DIE CASTING?

 

With the help of Aluminum as Die Casting metal, we can shape simple or complex objects easily. Aluminum offers a thin wall thickness as a property, which helps to shape objects perfectly around the corners. One of the most noteworthy benefits Aluminum Die Casting holds is that it creates lighter parts. Through Aluminum, Die Casting became fast, which means a high rate of production.

Products through Aluminum Die Casting extend the corrosion resistance and increase the lifetime of manufactured objects. Aluminum is monolithic, which means it tightly couple interdependent changes and increases the solidity of parts. Aluminum Die Casting is an efficient and economical alternative to other processes. More note-worthy quality benefits Aluminum Die Casting provides are the following:

  • Easy for mass production: Since Aluminum die casting is made from die casting mold. Little or no machining is required as tens of thousands of identical castings can be produced before additional tooling is required. So, it’s straightforward to put on mass production.
  • Dimensional accuracy and stability: Through Aluminum Die Casting, we produce parts that are durable and dimensionally stable. They are also head resistance.
  • Strength and weight: Aluminum Die-Cast parts are more durable and lighter than any other molding having the same dimensions.
  • Simplified Assembly: Aluminum Die-Casting provides; Integral fastening elements, which are studs, bosses, and etc. It made to tap drill sizes quickly & accurately. Holes also can be cored much quicker.

Some secondary benefits of using Aluminum Die Casting are:

  • It provides complex shapes within closer tolerances
  • Little or no machining is required and have a high rate of production
  • Provide parts that are dimensionally stable, durable, and have the appearance of quality.
  • Aluminum Die Casting can be produced with thinner walls.
  • Can produce thousands of identical castings within a specified tolerance
  • It can be produced with surface simulating a wide variety of textures
  • It provides integral fastening elements which can result in assembly economies.

 

WHAT ARE THE CHARACTERISTICS OF ALUMINUM DIE CASTING ALLOYS?

 

As you know, Aluminum castings are lightweight and can withstand the highest operating temperatures of all die casting alloys.

Aluminum alloys have some unique characteristics. For instance, aluminum alloys can outstand corrosion resistance and have good strength and hardness.

Aluminum alloys also have EMI & RFI shielding properties, excellent thermal conductivity, and high electrical conductivity.

Furthermore, Aluminum alloys have excellent finishing characteristics and are fully recyclable.

 

WHAT ARE THE TECHNIQUES USED IN ALUMINUM DIE CASTING?

 

 

Aluminum can be Die Cast with the help of five different classified techniques. High pressure die-casting, low pressure die-casting, gravity die-casting, vacuum die-casting, and squeeze die casting. The most well-known preferred and unique technique got used High pressure die casting. High pressure die-casting representing >50% of all light alloy casting production.

Furthermore, low-pressure die casting represents >20%, and gravity die-cast represents the rest.

 


 

Vacuum and squeeze die casting are small but growing recently introduced Aluminum Die Casting techniques.

 

 

WHAT IS THE IMPORTANCE OF ALUMINUM DIE CASTING?

 

It’s a great deal to cast-aluminum because of its unique properties and characteristics. Parts die-cast with aluminum alloys holds excellent strength and perform high-quality as compared to its predecessors like Zinc and Magnesium. Powerful aluminum alloys industries use the most are A380, 383 (ADC12), Alsi12, and Alsi9Cu.

Now, for example, Take A380 because it’s the most commonly specified aluminum alloy and considered the best from any other. Aluminum Die-Casting offers an excellent combination of casting and thermal & mechanical properties. It is also resistant to hot cracking and exhibits pressure tightness.

The above are some of the most suitable reasons why Aluminum is considered so essential and nearly necessary in die-casting.

 

WHAT ARE THE TYPES OF ALUMINUM DIE CASTING TOOLING?

 

There are four identical and most common types of Aluminum die casting tooling.

  • Single-Cavity Die

It produced one component at one time and considered best for complex shapes and large parts.

  • Multiple-Cavity Die

It produces multiple, identical, and mostly small parts.

  • Unit Die

Unit-Die is a unique way to cast different shapes of parts at a single time.

  • Combination Die

As its name reflects, it’s a combination of other types of Aluminum die casting and works as a single unit.

 

WHAT IS THE HISTORY OF ALUMINUM DIE CASTING?

 

It’s all started with the printing industry in the mid-1800s, and that’s when they invented the die casting equipment.At that time, portable typing machines required a large number of letters and punctuation marks all in a single unit.

That’s when die casting started, and from that day to this one, it quickly spread to other industries.

Aluminum has been around a long time. At first, Aluminum Die Casting is used by pressure injection in the mid-1800s. From that day to the next 20 years, the process of Aluminum Die Casting limited to printers’ type.

By 1892, commercial applications include parts of photography, and mass production of many types of parts started to manufactured.

Today, there is nothing more famous than Aluminum in Die Casting.

It is used in many part manufacturing products, such as Automobile parts, Airplane parts, light fixture parts, and tool parts.

 

WHEN AND WHO INVENTED THE ALUMINUM DIE CASTING?

 

 

The equipment for Die Casting Aluminum was invented in 1838, and A patent was rewarded for its first-time production to Sturges.

Sturges was the lucky man who came up with this idea.

Otto Mergenthaler gained popularity for his invention of the linotype machine in 1885, that’s when the manufacturing of parts started.

 

 

WHAT IS ALUMINUM DIE CASTING PROCESS?

 

It defines the process through which a mold is shaped into a part.

The Aluminum Die Casting process implements a mold often capable of producing thousands of casting in rapid succession.

The die must be made in at least the last two sections to permit the removal of aluminum casting.

The cycle of casting begins with the two die halves, and they’re clamped tightly together by die-casting press.

Malted/liquid Aluminum is injected into the die cavity where it solidifies itself quickly.

In the machine, these sections are mounted securely and are arranged that one is stationary while the other is moveable.

Die halves are drawn apart, and that’s when casting is injected.

Dies of die casting can be simple/intricate, having cores, moveable slides, or other sections depending on the complexity of the cast.

Sometimes machines use mechanisms actuated by hydraulic cylinders to achieve locking. Mostly use direct-acting hydraulic pressure.

Aluminum Die Casting machines very fundamentally only in the method used to inject molten Aluminum to die.

 

 

WHAT UNIQUE EQUIPMENT’S USED FOR ALUMINUM DIE CASTING?

 

When it comes to the equipment for Aluminum die casting, there are three basic types of die casting mechanisms used in Aluminum die casting machine.

 

  • Prototyping equipment

Mazak 7-axis turning & milling machine

Mazak/Hass 5axis CNC machine

 

  • 3-axis CNC machine center

4-axis CNC machine center

CNC Lathes

 

  • Die Casting equipment

TATUNG-OKUMA KGS-615AHD Grinder

Shenyang Machine Z3050*16/1 Drilling

 

  • Juli MJ034W Sawer

Shanghai 2nd Machine C6250A Lather

EDM Korea YIHAWJET Taiwan

Sodick Wire cutting machine

 

  • QC instruments of Aluminum Die Casting equipment

Spectrum Meter

CMM

 

  • X-Ray Detector

Imaging measurement instrument

Digital Caliper

Cleanliness Testing machine

 

  • ZEISS CMM

Die Casting Equipment is rated and categorized by how much clamping force they can apply. Typically, the rating is between 2500 and 25400 kg (400 and 4000 st).

 

WHAT IS COLD-CHAMBER ALUMINUM DIE CASTING?

 

Cold-chamber is logically a name of the mechanism through which Aluminum is die-casted.

Cold-Chamber machines are perfect when casting aluminum alloys.

The process for these machines starts with melting Aluminum in a separate furnace.

Afterward, a perfect amount of molten Aluminum is transported to the cold-chamber machine where it is fed into an unheated shot chamber, which is also called the injection cylinder.

This shot is then forced into the die by hydraulic/mechanical piston. The advantages of using this equipment are;

  • This procedure can make denser aluminum castings
  • Fast cycle times (Approx. 8 cycles/min)

 

WHY IS ALUMINUM NOT BEING CAST IN A HOT-CHAMBER DIE CASTING MACHINE?

 

Our industry doesn’t prefer using the hot-chamber mechanism. Because when Aluminum is used and mostly, it picks up some of the iron while in the molted pool.

It also increases the percentage of defected parts and also decreased the quality of the final manufactured products.

Hot-chamber die casting is known as gooseneck machines. To feed the die, they rely upon a pool of molten Aluminum.

The piston of the die casting machine is retracted and allows molten Aluminum to fill the “gooseneck” at the beginning of its process cycle.

These machines are compatible with having two types of pistons, the first is pneumatic-powered, and the second is hydraulic-powered.

The pneumatic-/hydraulic-powered piston then forces Aluminum out of the gooseneck into a die, and that’s where Aluminum got mixed with iron.That’s the reason why we use clod-chamber machines so you can get quality and top-notch products.

 

 

WHAT VALUES GOT ADDED IN ALUMINUM DIE CASTING?

 

To confirm that the final product is reliable, we perform a series of steps to verify its quality.

After casting, the parts go for heat-treatment. Afterward, CNC machining is performed on them and then sent for laser cutting.The parts which made it so far are e-coated and passivated. Then assembled and ensured that the parts are ready to deliver to you.

 

WHAT ARE THE BENEFITS OF ISO9001-2015 CERTIFIED ALUMINUM DIE-CASTED PRODUCT?

 

Aluminum Die Casting is committed to providing you with royal-quality products.

Quality assurance is an integral section of our business operation. That allows us to obtain the highest operating efficiency.

Our every product is ISO9001:2015 certified and provides benefits like;

  • Improved service, quality, and reliability
  • Crystal-clear product structures, processes, tasks, and responsibilities
  • Enhanced material flow management
  • on-time delivery
  • Right first-time attitude
  • Structured problem-solving
  • Kaizen-driven activities that support minimal throughput times
  • Risk management is according to ISO-9001 standard.

 

WHAT ARE THE NEW PROCESS TECHNOLOGIES USED IN ALUMINUM DIE CASTING?

 

There’ve been a lot of challenges in die casting to establish casting processes to produce high-integrity components from aluminum alloys.

Advancing in new casting technology has been in pressure die casting. In particular, to obtain mold-filling at low speed.

It can be achieved by using innovative filling processes with aluminum alloys in liquid/semisolid state.

Different new process techniques have been developed such as;

  • High-pressure die casting (HPDC)

  • Cosworth process

  • Low-pressure systems

  • Squeeze casting

  • Indirect squeeze casting

  • Aluminum compression forming (ACF)

  • Semisolid metal (SSM) processing

 

Semisolid forming includes thermoforming & reforming.

During the semisolid casting process, preheating by introduction is required to obtain the same temp.

And the same liquid fraction through the billet in a short time. Thixocasting in the semisolid state help avoiding turbulence during mold-filling.

 

WHAT ARE THE QUALITY CONTROL PROCEDURES OF ALUMINUM DIE CASTING?

 

We need to ensure the final product before it got delivered to our clients. We ensure the product according to the two widely known QC standards;

  • ISO9001:2015
  • IATF16949:2016

QC procedures in regards to Aluminum Die Casting industries need to follow;

  • Ability to Quickly deliver products that meet customers’ requirements
  • Facilitating opportunities to enhance customer satisfaction
  • Addressing risks & opportunities which are associated with its objectives & contexts
  • The ability to demonstrate-conformity to specified requirements of the quality-management system
  • Achievement of effective process performance
  • All processes must be PDCA (Plan-Do-Check-Art) cycle applied

QC procedures in regards to ISO9001:2015 and IATF16949:2016;

  • Continuous Improvement of product and procedure
  • Defect prevention
  • Reducing waste
  • product safety
  • Risk management
  • Contingency planning
  • Requirements for embedded software
  • Change and warranty management
  • Management of sub-tier suppliers

 

HOW TOOLS AND PARTS ARE DESIGNED AND MANUFACTURED BY DIE CASTING ALUMINUM?

 

There are many techniques & technologies of Aluminum Die Casting, and all of them simply work on a fundamental principle.

In the past, tools were manufactured based on the drawing. In the present, designers work with 3D-CAD data and use state-of-the-art IT technologies.

Through this, the design is created, tested, and proceed to start production.

The process of designing aluminum tools/parts takes place in the die casting machine, which is mostly a cold-chamber machine.

First, we melt the Aluminum and pour it into a container and close the mold.

When the mold is closed, the aluminum melt is pressed into the shape under a pressure of up to 1200 bar.

And we are achieving maximum mold filling speeds of 150 m/s (540 km/h).

Clamping forces & high closing is required to press the mold halves against each other. Afterward, we keep the mold closed at up to 45000 kN (4500 t).

With the help of such high forces, large-sized cast parts can be manufactured.

Then we left it to cool down. After, the mold halves open, and the casted part is ejected and conveyed for further processing.

These after processes add values to the die-casted aluminum part and make them supreme-quality products.

 

WHAT IS ALUMINUM RAPID PROTOTYPING?

 

Aluminum Rapid Prototyping is the process through which prototyping’s built through cutting material from a solid block of Aluminum.

Present design factors & marketing realities push the engineers/industries to come up with their finished products, by spending the minimum possible time and budget during the design phase.

Rapid prototyping is used to fill-up these market demands.

Overview of Aluminum Rapid Prototyping Process:

Aluminum Rapid Prototyping is a prime method of prototyping manufacturing.

There are several modern and traditional ways to have your prototype come into existence.

Here we’ll be discussing the CNC manufacturing technique for Aluminum Rapid Prototyping.

Which process to carry out is depends upon which sort of machine you’re using for CNC prototyping.

You’ve to insert in the system with CAD design and have it converted to vectors. The reason for this conversion is that the machine can read off the coordinates.

Once this soft-file is uploaded and vectors are traced, the tools and their paths are selected to cut the block into shape.

It can be of .25 inches v-bit or .75 inches core box bit. Along with the cutting depth, the speed of cutting can also be altered.

Once the tool, its operating speed, and the depth of cutting are selected, the toolpath is then transferred to the CNC machine.

You can either cut outside/inside the vectors or can track them. The method of cutting is based upon the machine, its operator, and design complexity.

The output vectors are then converted to G-code. The CNC router is jogged right at the center of the block also touches the face of it.

The CNC machine then reads the G-Code and starts a rapid prototyping process.

 

WHAT IS ADDITIVE&SUBTRACTIVE ALUMINUM PROTOTYPING?

 

These are two main techniques of Aluminum rapid prototyping, and their processes are also briefly described in the following figure.

Additive Aluminum prototyping:

 

It’s especially CNC Aluminum that is processed under virtual 3D designs to build up the prototype via depositing aluminum layers.

 

The aluminum prototypes are built from bottom-up. Laser-sintering & 3D printing is some of the best examples of addictive rapid prototyping.

 

Benefits of using additive rapid prototyping:

  • Reduce tooling costs
  • Fast production
  • Quickly test intricate product designs
  • Better product quality

 

Subtractive Aluminum Prototyping:

 

It’s the process through which prototyping is built through the cutting of metals by using a block of Aluminum. In regards to this process, prototypes are made from top to bottom.This prototyping also is done via CNC machining, which includes milling, turning, milling, and other standard machining processes.In these times, Industries mostly rely on Subtractive rapid prototyping because it’s faster, economical, and better as compared to its counterparts.

Benefits of using rapid subtractive prototyping:

  • Produces lower, more capable tolerances
  • Results in smoother surfaces
  • Manufactured parts intended for long-term or high-stress use

 

WHAT ARE THE BENEFITS OF ALUMINUM RAPID PROTOTYPING?

 

Aluminum Rapid Prototyping is both progressive & practical. Using these unique techniques enables you to gain significant benefits:

  • Speed: Aluminum Rapid Prototyping produces results quickly, and it’s also understood that the prototyping is rapid but never rushed.

 

  • Better proof of testing results: Precision is the basis of Aluminum Rapid Prototyping. An accurate and perfect prototype is critical in evaluating/verifying the product’s function, fit, and finish.

 

  • Speed in transitioning to production: It’s easy to make anything for once, but what about the second time, and what about every time after that one?

 

Rapid prototyping process every time represents the production process, checking consistency, and quickly start the process of production.

 

  • Product Refinement: Once the rapid prototyping process is over, it became straightforward to implement revision and modification of the products.
  • Time to customers: Rapid prototyping leads to rapid production, which leads to timely distribution and which leads to short-time delivery to customers and faster service.

 

HOW MANY STAGES ARE IN THE HIGH-PRESSURE ALUMINUM DIE CASTING PROCESS?

 

Aluminum Die Casting Process depends upon the technique/mechanism used for die casting.

We’ll overview the process of one of the techniques.

High-pressure Aluminum Die Casting Process Stages:

This’s also known as traditional Aluminum die casting and consists of four process stages.

  • Preparing the Mold: During this initial step, the manufacturer applies a lubricant to the interior walls of the mold, because lubricant regulates the temperature of the frames and also allowing for easier removal of the casting.

 

  • Injection: The manufacturer injects the die mold with molten metal. The frame must be closed and sealed during this step.

 

The molten metal may be injected into the mold at a pressure of between 1500 to 25000 pounds/square inch (PSI).

 

The mold maintains the pressure until the molten metal has cooled and solidified.

 

  • Cavity Ejection: Afterward, the manufacturer ejects the newly made cavity from the mold. The mold features ejector pins that, when engaged, release the hole.

 

  • Shakeout: During this step, the manufacturer separates any scrap metal from the newly created cavity.

 

Sometimes high-pressure die casting produces excess scrap metal; hence it’s not uncommon for it.

 

Some may stick inside the mold. As a result, the scrap metal must be removed before the frame can be reused.

 

HOW MANY STAGES ARE IN THE COLD-CHAMBER ALUMINUM DIE CASTING PROCESS?

 

Cold-chamber die casting is ideal for Aluminum because of its high melting point.During this process, Aluminum is liquefied in a furnace at extremely high temperatures. Later, it landed into a cold chamber to be injected into the die.

The structure of cold-chamber Aluminum die casting machine components is shown below.Injection pressure that can be obtained from the cold-chamber die casting machine is over 10000 psi or 70000 KPa.The sequence of the cold-chamber die casting process operation is plunger, cavity, core, ejector pins, and ejector dies.

 

This process consists of three stages.

  • Start-Stage: The process starts with the die is closed, and the molten metal is ladled into the shot sleeve.

 

  • Mid-Stage: The plunger pushes the molten metal into the die cavity, where it is held under pressure for several minutes until it solidifies.

 

  • Finish-Stage: The die opens, and the plunger advances to ensure the casting remains in the die and ejector pins push the cast out.

 

Afterward, the plunger returns to its original position.

 

WHAT IS THE MELTING POINT OF ALUMINUM DIE CASTING ALLOYS?

 

This chemical element, with the symbol Al and atomic number 13, is a silvery-white soft, non-magnetic metal. And it makes up about 8% of the earth’s crust.

The point at which Aluminum starts to melt is 660.3 degrees Celsius, and the point at which it starts boiling is 2470 degrees Celsius.

 

WHAT ARE ALUMINUM DIE CASTING ALLOYS?

 

It means that aluminum alloys which are considered as perfect while die casting. The few which are belong to this category are ADC12, A380, AlSi12, and AlSi9Cu.

Aluminum die-casting alloys are widely used in engineering structures/components where light weight or corrosion resistance is required.

Alloys that are mostly composed of Aluminum have been nearly essential in aerospace manufacturing since the introduction of metal-skinned aircraft.

Before choosing the right Aluminum alloy for your product, consider the following essential factors to focus;

  • Formability/workability
  • Weldability
  • Machining
  • Corrosion Resistance
  • Heat Treating
  • Strength
  • Typical end-use applications.

 

WHAT ARE THE BASICS OF DIE CASTING ALUMINUM?

 

What is your need? That’s an essential question during die-casting Aluminum because everything depends upon the final product our customer requires.

There are some basic pre-procedures before die-casting Aluminum and categorized into four parts.

  • Knowing your product: First, identify the product, then plan it through.
  • Aluminum alloy selection: Aluminum alloys have different values of properties. After identifying the product, the best alloy got selected.
  • Preferred technique: After alloy selection, according to product size, shape, and design complexity, the right method got chosen.
  • Selection of Die: It’s the final stage and relies upon the product design. From single-cavity, multiple-cavity, unit, and combination Die one tooling got selected according to design complexity and size.

 

WHAT FACTORS AFFECT THE QUALITY OF ALUMINUM DIE CASTING ALLOYS?

 

The quality requirements of Aluminum die casting alloys are surface roughness, physical & mechanical properties, size, and shape.Furthermore, the presence of cracks, holes, inclusions, segregation, wear resistance, corrosion resistance, etc.

The question is, what factors affect the quality of Aluminum Die Casting Alloys?

The performance and quality of Aluminum die casting alloys have an essential relationship with the four below described factors:

  • Reasonable casting process: To confirm quality aluminum alloy die casting parts, the right kind of split-face, the design/shape, the core-method,the rational-setting of forging. The mouth & pouring system should be picked based on the structure of aluminum alloy, the weight, the size, the character of the alloy, and the production conditions.

 

  • Design Technology of Aluminum Die-Casting Alloy: During the design phase, in addition to working conditions and the material performance to determine the geometric product shape, size, angle of the casting alloy, and casting characteristics.Size also affects and can create shrinkage, stress, and other problems, to avoid them, our industry operates according to ISO and IATF standards and give quality output product to our customers.

 

  • Quality of raw Aluminum for casting: Choosing inferior raw materials may cause defects to the final product, such as porosity, pinhole, and slag, which can affect the appearance quality and internal quality of aluminum alloy die casting, which also can cause casting to be scrapped.Our industry operates on pre-defined steps and filtering of raw material before process and eliminates the weak parts.

 

  • Process operations: It is necessary to establish operating procedures for Aluminum die casting alloys.We improved the level of technical workers and made the process adequately implemented to achieve maximum accuracy.

 

WHAT DOES ONE-STEP ALUMINUM DIE CASTING SOLUTIONS MEANS?

 

This is the definition of precise and quality Aluminum die casting products manufacturing.

Industries that only die-cast aluminum and specialized in it called one-step Aluminum die casting solution.

Similar to the term “One solution for all your problems.”

From part conception & prototyping through finalized products, one-step solution industries provide integrated services.

These industries provide facilities like:

  • Rapid prototyping
  • Die Casting Tooling
  • Aluminum Die Casting Production
  • CNC Machining
  • Surface Finishing
  • Shot Blasting
  • Powder Coating
  • Liquid Painting
  • Electroless Nickel
  • Anodization
  • Silk Screening
  • Pad Screening
  • Chromate-Surtec 650

 

Our industry is one of them and specialized in designing and manufacturing every type of aluminum product.

 

WHICH STRONG MECHANICAL PROPERTIES DOES ALUMINUM DIE CASTING ALLOYS TO HOLD?

 

Aluminum alloys like ADC12 and A380 have strong mechanical properties.These are also the most preferred aluminum alloys and also produces quality results.

Below are the mechanical properties in which aluminum alloys are the strongest alongside with the related value.

  • Tensile Strength [46000-47000 PSI]
  • Yield Strength [23000-24000 PSI (0.2% Offset)]
  • Shear Strength [26000-27000 PSI]
  • Elongation [3.5 % inch per inch]
  • Hardness [80-85 BHN]
  • Impact Strength [3 Ft. Lb. (Charpy)]
  • Youngs Modulus [10.3 PSI x 10-6]

These are standard and accurate measurements.

 

WHICH STRONG PHYSICAL PROPERTIES DOES ALUMINUM DIE CASTING ALLOYS HOLD?

 

Aluminum alloys like ADC12, A380, and AlSi12 have strong physical properties.

These are also the most preferred aluminum alloys and also produces quality results.

Below are the physical properties in which aluminum alloys are the strongest alongside with the related value.

  • Density [0.095-0.099 Lb./Cubic Inch]
  • Melting Range [1000-1105 Degree F]
  • Coefficient of Thermal [12.1-12.2 Expansion u In/In Degree F]
  • Thermal Conductivity [55.6-65.3 BTU/Ft. Hr. Degree F]
  • Electrical Conductivity [23-30 %IACS]
  • Melting Point [2600-degree F]

These are standard and accurate measurements.

 

WHAT ARE ZINC AND ALUMINUM DIE CASTING COMPOSITION?

 

Mixing Aluminum with zinc and manufacturing a die casting product with it, called zinc & Aluminum die casting composition.

It outputs a reliable product that has both Aluminum and zinc properties and more durable in some unique cases.

To achieve this purpose, the Aluminum alloy ZA-27 is used mostly. It is a zinc-aluminum alloy and contains more Aluminum than a zinc group of alloys.

The number “27” represents the approx. Percentage of Aluminum the alloy contains.

Some benefits of doing so are the following:

 

  • ZA-27 has the highest aluminum content, most upper strength, high melting point, and low density.
  • This zinc alloy exhibits bearing properties that allow carrying to be designed into the casting of applications.
  • Its high casting temperature requires the cold-chamber process.

 

WHAT ARE THE PROPERTIES OF ZINC AND ALUMINUM DIE CASTING COMPOSITION?

 

Zinc and Aluminum combined are preferred in some unique cases and have the following mechanical and physical properties.

Mechanical properties of zinc and Aluminum die casting composition:

  • Elongation [3 % in 50mm]
  • Tensile Strength [425 MPa]
  • Yield Strength (0.2%) [376 MPa]
  • Impact Strength [12.8 J]
  • Shear Strength [325 MPa]
  • Hardness [119 Brinell HB]
  • Process [Cold Chamber Die Casting]

 

Physical properties of zinc and Aluminum die casting composition:

  • Density [5.00 g/cm(3)]
  • Melting Point (Average +/- 50) [431 degrees C]
  • Thermal conductivity [123 W/mK]
  • Coefficient of Thermal Expansion [26.0 um/mK]
  • Electrical Conductivity [29.7 % IACS]
  • Process [Cold Chamber Die Casting]

 

WHAT ARE THE DETAILED SPECIFICATIONS OF ALUMINUM DIE CASTING ALLOYS?

 

Aluminum is the world’s most abundant metal, and the versatility of it makes it the most widely used metal after steel.

There are some reasons behind its full, which are the factors of its quality products.

And when it comes to die-casting aluminum alloys, they have some unique specifications, which are briefly discussed below.

  • Strength to Weight Ratio: Aluminum alloys have a density around 1/3 that of steel and is used on a large scale in applications where high-strength and low-weight are required.

 

This includes automobiles where low mass results in higher load capacity and reduced fuel consumption.

 

  • Corrosion Resistance: When the surface of aluminum alloy is exposed to air, a protective and safe oxide coating forms.

 

This oxide layer can be further enhanced with surfer treatments. These surface treatments, such as anodizing, improve, and help to build a quality alloy.

 

  • Electrical and Thermal Conductivity: Aluminum is a perfect conductor of heat and electricity. The most significant advantage of Aluminum is that by weight, the conductivity of it is around twice that of copper.

 

Therefore, these can be used for all electrical conduction applications, including domestic-wiring.

 

High voltage power lines these days use Aluminum rather than copper because of its weight considerations.

 

They do, however, have low strength and need to be reinforced with galvanized.

 

  • Light and Heat Reflectivity: Aluminum is an excellent reflector of light and heat, making it an ideal material for light filling, thermal rescue blankets, and architectural-insulation.

 

  • Toxicity: Aluminum is non-toxic and also does not release any odors or taint products with which it is in contact. This makes it suitable for use in packaging for sensitive products.

 

  • Recycling: When Aluminum is recycled, there are no degradations in properties. Furthermore, the recycling of Aluminum only requires approx—5 % of input energy.

 

IS THERE ANY EFFECT OF RECYCLING ALUMINUM DIE CASTING ON THE ENVIRONMENT?

 

The aluminum industry is very serious about the environmental impact of its activities.

The mining and smelting of Aluminum and the disposal of red mud can have a significant environmental impact if not done correctly.

Our industry is proud of its efforts and achievements in rehabilitating open-cut mine sites and restoring flora.

Thanks to the awareness and technology, the red mud disposal areas are now being successfully revegetated.

Through the use of specialist and expert scrubbing system, the environmental requirements are being met on potline emissions.

Aluminum Die Casting is environmentally friendly and completely recyclable. The combination of two remarkable properties of Aluminum makes the need to recycle the metal.

The first of these factors is that there is no difference between recycled and virgin Aluminum.

The second is that recycled Aluminum only uses 5% of input energy to produce virgin material.

Currently, approximately 60% of aluminum metal is recycled at the end of its lifecycle. But this percentage can be improved.

 

 

DO THE PRODUCTS MANUFACTURED THROUGH ALUMINUM DIE CASTING HAVE GOOD ELECTRICAL OR THERMAL CONDUCTIVITY?

 

In physics, the term “conductivity” has several meanings. For metals such as Aluminum, it refers to the transfer of either electrical or thermal energy, since the loosely-bound electrons found in minerals conduct both heat and electricity.

Thermal Conductivity in Aluminum Die Casted products:

Means, the ability of a material to conduct heat and generally measured in watts per kelvin per meter.

Materials with good thermal conductivity transmit a massive amount of hearing quickly. Pure Aluminum has a thermal conductivity of about 235 watts per kelvin per meter.

Heat sinks for electric parts are made of aluminum alloys due to the metal’s excellent thermal conductivity.

Electrical Conductivity in Aluminum Die Casted Products:

This means the ability of a material to conduct current, and it’s generally measured in siemens per meter.

Suitable electrical conductors are preferred for wiring and connecting. Naturally, Pure Aluminum metal has an electrical conductivity above 38 million siemens/meter.

 

HOW ARE ADVANCED ALUMINUM DIE CASTING MACHINES BEING PROFITABLE?

 

With the development of industries such as motorcycles, automobiles, and household applicants, Aluminum die-casting technology has achieved extremely rapid growth.

The modern die-casting machine has a series of industrial casting machines that take the molten metal hydraulically.

Then transfer it into the mold under pressure to form a solid aluminum casting after cooling.

These advance ADC machines are profitable because they:

  • Reduce the % of defects per batch
  • Enhance product quality
  • Can recycle a considerable amount of waste
  • Increase the production rate

 

CAN COMPLEX SHAPES BE MADE THROUGH ALUMINUM DIE CASTING?

 

Die Casting Aluminum can help us design shapes like:

  • Thin-Walled: Complex
  • Solid: Cylindrical
  • Solid: Cubic
  • Solid: Complex

with the feasibility of:

  • Flat
  • Thin-walled: Cylindrical
  • Thin-walled: Cubic.

Aluminum die-casted complex shapes could be from 0.5 oz to 500 lbs.

Aluminum can form complex shapes of high strength and also gives them an excellent surface finishing and accuracies like engine components, pump components, and appliance housing.

 

WHAT ARE THE REQUIREMENTS AND ESSENTIALS TO START AN ALUMINUM DIE CASTING PROCESS?

 

Aluminum Die Casting process is of high-level importance. Before starting this process, four essential things need to be considered and discussed.

  • Identify your needs: Selection of an Aluminum Alloys is the most important part before starting the die casting process.

 

What part you want defines what properties you are preferring and what features should be the top priority according to your choice.

 

After this information, the most fit aluminum alloy got selected and chosen to process further.

 

  • Inspection: The pre-processed material then inspected for defects and filtered until the output is 100% processed and useable Aluminum.

 

  • Process selection: A most suitable aluminum die casting process and mechanism is selected.

 

Sometimes a prototype of the final product is designed and discussed for a better product outcome purpose.

 

  • Tooling selection: Based on the product output design, A cavity die is chosen.

 

Single, multiple, unit, or combined die which one to choose depends upon the production requirement and design complexity.

 

WHAT IS ALUMINUM A380 ALLOYS?

 

A380 is an aluminum alloy that offers the best combination of casting and mechanical & thermal properties.

A380 is the most common aluminum alloy and considered the best. It exhibits a perfect amount of fluidity, pressure tightness, and resistance to hot cracking.

A380 has a quite good machinability.

The applications of A380 are the following:

  • Chassis for electrical equipment
  • Engine brackets
  • Gearbox cases
  • Household furniture
  • Power
  • Hand tools.

 

Because of the possibility of blistering of pressure die casting, it is becoming unusual to heat-treat it.

However, its properties can be improved by giving it a T5 or a T2 temper casting.

Mostly T5 is given because the requirements of treating define that the casting must have excellent internal soundness.

 

WHAT ARE THE ADVANTAGES OF USING A380 ALUMINUM ALLOY IN DIE CASTING?

 

A380 is the most common and highly used aluminum alloy because of its unique properties and advantages.

Below are the reasons described that why A380 is so much favorable.

  1. It’s availability in the industry
  2. The unique values it offers to our customers
  • Aluminum Alloy A380’s ability to resist hot cracking & corrosion
  1. High level of strength at high-temperatures
  2. A380’s ability to perform well at high-temperatures
  3. During an Aluminum Die, Casting Process A380 offers anti-soldering properties
  • A380 helps in ease of machining
  • Polishing and finishing is also becoming very easy on A380
  1. It has more versatility in finishing options
  2. A380’s tensile strength
  3. It’s lightweight

 

WHAT ARE THE MECHANICAL AND PHYSICAL PROPERTIES OF A380 ALUMINUM ALLOY?

 

We prefer A380 because of its strong mechanical and physical properties.

Mechanical properties of A380:

  • Tensile Strength: 324 MPa
  • Yield Strength: 160 Mpa
  • Impact Strength: 4 J
  • Shear Strength: 190 MPa
  • Hardness: 80 Brinell (HB)
  • Elongation: 3.5 % in 50mm

The most preferred process for die-casting A380 is through Cold-Chamber Die Casting.

Physical properties of A380:

  • Density: 2.71 g/cm (power 3)
  • Melting Point: 566 degrees C
  • Thermal conductivity: 96 W/mK
  • Coefficient of Thermal Expansion: 21.8 um/m’k
  • Electrical Conductivity: 23.0 %IACS

 

WHAT IS ALUMINUM ADC12 ALLOYS?

 

Aluminum alloy ADC12 is also known as Alloy 383. It is considered as the most similar alloy to A380.

If your components are highly intricate, aluminum alloy ADC12 is your go. It has better corrosion resistance, and it is also lightweight.

If you are looking for ease of casting, ADC12 is the perfect alloy for that. It has excellent mechanical and physical properties and also dimensional stability.

Applications of ADC12 Aluminum Alloy:

  • Automotive parts
  • Casting products
  • Metallic machines & motor mobiles
  • Thermal camera parts
  • LED floods

ADC12 reduces manufacturing costs and facilitating the manufacturing process.

It has improved resistance to hot cracking and dies filling characteristics. ADC12 performance-to-price ration is very high.

 

WHAT ARE THE ADVANTAGES OF USING ADC12 ALLOY IN DIE CASTING?

 

Also known as A383 and considered as an alternative to A380 because of its most similar properties and uses.

Using ADC 12 is beneficial in many ways, and some of them are described below:

  1. ADC12 discharges little bit of gas
  2. It’s easy to bake out
  • ADC12 is lightweight
  1. Little damage against radioactivity is used
  2. Good fluidity
  3. Excellent castability
  • High mechanical properties
  • It is easy to have turbulent flow through ADC12

 

 

WHAT ARE THE MECHANICAL AND PHYSICAL PROPERTIES OF ADC12 ALLOY?

 

We prefer ADC12 because of its high & unique mechanical properties.

Mechanical properties of ADC12 or A383:

  • Elongation: 3.5 % in 50mm
  • Tensile Strength: 310 MPa
  • Yield Strength (0.2%): 150 Mpa
  • Impact Strength: 4 J
  • Hardness: 75 Brinell (HB)

With these kinds of mechanical properties, it is perfect use in Cold Chamber Aluminum Die Casting.

Physical properties of ADC12 or A383:

  • Density: 2.74 g/cm (power 3)
  • Melting Point (Average +/- 50): 549 degrees C
  • Thermal conductivity: 96 W/mK
  • Coefficient of Thermal Expansion: 21.1 um/m’k
  • Electrical Conductivity: 230 % IACS

 

WHAT IS ALSI12 DIE CASTING ALLOYS?

 

Al for Aluminum and Si for Silicon. AlSi12 is an Aluminum Silicon mixture alloy, which is mostly used in die casting.

It is known for its unique mechanical properties. It’s mostly used in welding cast aluminum parts and reasonably suitable as brazing alloy with suitable flux.

AlSi12 is CE approved and now used by many high-level industries. AlSi12 die cast parts can be seen in many areas.

Applications of AlSi12 Die Casting alloy are:

  • AlSi12 is a welding and brazing alloy
  • This alloy is generally used for die casting brazing aluminum sheets
  • Used in extrusions and casting products

AlSi12 can be of a different color; mostly, it changes its color after anodizing the welding.

 

WHAT ARE THE ADVANTAGES OF USING ALSI12 ALLOY IN DIE CASTING?

 

Among the Aluminum die casting alloys, AlSi12 is the first & the most crucial die casting alloys primarily. Because of its excellent and elegant casting characteristics.

There are very few elements that exist that can be possibly added to Aluminum, and the silicon is one of them.

One of the most significant advantages’ silicon carries within itself is without losing its weight, it can be added into Aluminum.

Establishment of compaction load:

To achieve optimal compaction density, trial compaction was done for AlSi12 aluminum die casting alloy.

A cylindrical die of 25.4mm diameter was used to obtain cylindrical specimens as /ASTM B-925.

After the compaction process, it is found that there is no change in the density of AlSi12, which makes it even more unique.

Values of AlSi12 aluminum die casting hardness:

  1. Material: AlSi12
  2. Load: 160 KN
  • Hardness: 13.99 HRB

These numbers may be difficult to understand for some of you, so let us translate it into words.

The hardness of AlSi12 alloy is way higher than A380 or ADC because alongside with Aluminum, silicon properties make a difference.

Tensile strength of AlSi12 aluminum die casting alloy:

We have done some tensile tests through the Universal Testing Machine of this alloy.

The load elongation date is captured by the software and afterward further analyzed for detailed information. This test was precisely prepared as per ASTM standards.

And in results, it is evident that AlSi12 aluminum alloy with 0.5% weight percentage has the highest tensile strength value as compared to the other aluminum alloys.

The above were some standards and test results of AlSi12, which perfectly clarify the advantages of using it in die casting.

 

 

WHAT ARE THE MECHANICAL AND PHYSICAL PROPERTIES OF ALSI12 ALLOY?

 

We use aluminum alloy AlSi12 in die casting because of its hardness and tensile strength properties, which are the best and useful in many cases.

Mechanical properties of AlSi12:

  • Tensile Strength: 125 – 150 N/mm (power 2)
  • Yield Strength: 70 – 85 N/mm (power 2)
  • Elongation: 15 – 30 %
  • Heat Treatment: >170 “RM” N/mm (power 2)
  • Impact Energy: -60 degrees to -20 J “IOS-V.”

Physical properties of AlSi12:

  • Density: 2.66 g/cm (power 3)
  • Melting Point (Average +/- 50): 573 – 585 degrees C
  • Thermal conductivity: 130 – 190 W/mK
  • Coefficient of Thermal Expansion: 21.0 um/m’k
  • Elongation A: 2 – 3 %
  • Young’s modulus: Approx. 75. 10 (power 3) N/mm (power 2)

 

WHAT IS ALSI9CU DIE CASTING ALLOY?

 

AlSi9Cu is an aluminum die casting alloy that is a mixture of three material Aluminum, Silicon, and Copper.

It’s a unique die casting alloy, and only some of the specialized industries used them.

AlSi9Cu has some of the most robust mechanical properties and is a solution to manufacture lightweight automotive parts.

AlSi9Cu has a high specific strength and lightweight.

AlSi9Cu applications are the following:

  • AlSi9Cu is used widely for engine components
  • Pistons & Pullies are mostly manufactured by using AlSi9Cu
  • Used in industries demands of aerospace
  • Used in Commercial products

 

WHAT ARE THE ADVANTAGES OF USING ALSI9CU ALUMINUM ALLOY IN DIE CASTING?

 

Advantages/benefits of using AlSi9Cu die casting alloy:

  1. AlSi9Cu has a good toughness
  2. Is a high strength aluminum alloy
  • Has adequate damage tolerance capability
  1. Has good fatigue resistance
  2. Has good corrosion resistance

As you know that AlSi9Cu is lightweight and has a specific strength, and that’s the biggest reason for its use in complex and essential parts like engine components (pistons & pullies).

Naturally, AlSi9Cu has low hardness and low wear endurance, and to overcome this, we use a plasma nitriding technique.

 

WHAT ARE THE MECHANICAL AND PHYSICAL PROPERTIES OF ALSI9CU ALLOY?

 

AlSi9Cu is lightweight & very strong and mostly used in the manufacturing of complex parts in automobile and aerospace industries.

Mechanical properties of ADC12 or A383:

  • Elongation: 2.0 % in 50mm
  • Tensile Strength: 230 MPa
  • Yield Strength (0.2%): 190 Mpa
  • Bending strength: 8.0 N/mm (power 2)
  • Hardness: 75 Brinell (HB)

 

Physical properties of ADC12 or A383:

  • Density: 2.70 kg/dm
  • Melting Point (Average +/- 50): 577 degrees C
  • Thermal conductivity: 100 W/mK
  • Coefficient of Thermal Expansion: 20.0 um/m’k

 

HOW ALUMINUM DIE CASTING IS BEING BENEFICIAL FOR INDUSTRIES?

 

Aluminum Die Casting is an economical forming process.

Industries are adopting it quicker because of its high-end advantages and speed of producing hundreds of thousands of castings rapidly.

Supreme quality under a low cost of die-casting Aluminum is a reason why its spreading and industries are adopting it.

There are two core benefits of using Aluminum in die casting.

  • Low-cost equipment for customers
  • Faster production for Industries.

Industries adopting die casting because it’s the fastest process of manufacturing products/equipment and unique quality and enterprises adopting aluminum alloy in die casting because of its:

  • Splendid EMI/RFI isolation
  • Good processing properties
  • High electrical conductivity
  • High thermal conductivity
  • High corrosion resistance
  • High strength and hardness

 

WHAT DOES IT MEAN BY ALUMINUM DIE CASTING INJECTION?

 

It reflects a term mostly used in the die casting process. When a melted aluminum is poured into the furnace afterward, it is injected into the die cavity.

In the die casting machine, there is an injector used to run this mechanism.

More specifically, there is an injector in the die-casting machine used to inject the melted Aluminum into the cavity of die.

That injector is called Aluminum die casting injection.

 

WHY WE PREFER ALUMINUM DIE CASTING OVER INJECTION MOLDING?

 

When it comes to casting you to have an important decision to make…

Should you make your path using injection molding or Aluminum die casting? We are here to help you decide.

Let’s have a look at the significant advantages of each.

 

Benefits of Aluminum Die Casting:

  1. Die Casting is an efficient process with a high degree of accuracy
  2. No need for secondary operations to manufacture the final product
  • Can cast complicated designs more easily
  1. Manufacture high-quality products with better tolerance that will last longer

Benefits of Injection Molding:

  1. Production through injection molding is quicker due to flexibility in the molding process
  2. It can accommodate different materials
  • Fillers increase the strength of final manufactured products and that’s why we use them
  1. The efficient and delicate process with very accurate finishes

 

So why would you choose Aluminum die-casting over injection molding?

If you are looking to produce thousands of products quickly and inexpensively, then Aluminum die casting is your go.

On the other hand, injection molding is costly, and its machines and equipment can be somewhat expensive.

Also, if accuracy in design and final product design accuracy is your high priority or your products have a sophisticated design, then, in this case, Aluminum die casting win again and also a preferred option.

 

WHAT IS INJECTION MOLDING vs. ALUMINUM DIE CASTING?

 

The process of manufacturing parts is the same, whether you are using Aluminum die casting or injection molding.

You first make a soft copy of the design and prepare a die or a mold of the exact form as the part you are going to manufacture.

You then liquefy the material and use an extreme level of pressure to inject it into the die or the mold.

You then cool it and open the die for removing the final product (the term is also called “removing the shot”).

They are not the wholly same but also, and they have some variations in technique.

The significant difference between Aluminum die casting, and injection molding is that when it comes to injection molding, it uses plastic or polymers as raw material.

Injection molding can’t use aluminum alloy as raw metal.

If your choice is to go with injection molding, you will end up with plastic parts.

And if you are going to use Aluminum die casting, you will defiantly be going to end up with aluminum parts, which are way much more robust and accurate.

 

HOW ARE PRODUCTS MADE THROUGH ALUMINUM DIE CASTING?

 

To know the answer, we must have to discuss the process of manufacturing aluminum products.

Aluminum die casting is an aluminum parts manufacturing process that makes use of tooling dies, and producing high-end geometrically complex metal parts.

Inside the Aluminum die casting machine, die casting makes use of molten Aluminum, which is injected at high pressure into the die.

The aluminum casting varies in size & weight.

Some examples of Aluminum die castings are:

  • Engine components
  • Pump components
  • Appliance housing
  • Automobile components

 

When it comes to the environment, the Aluminum Die Casting is very friendly.

Since the low density of aluminum alloys can reduce wastes and scrap aluminum materials can be recycled.

 

WHAT PRODUCTS ARE MADE THROUGH ALUMINUM DIE CASTING?

 

Before we start discussing the products, we are going to divide them into segments.

Our industry focuses on professional markets, which are characterized by low to medium volume, high mix, and high requirements for quality reliability.

  • Medical & Health Care
  • Automotive Engine & Electronics
  • Communications & Networking
  • Smart Metering
  • Marine Electronics
  • Industrial & Commercial
  • Aerospace Electronics
  • LED Lighting

 

The following are some top products of Aluminum die casting automotive parts.

If you own an automotive part, it would be a great idea to check out aluminum die-casted parts for your products.

  • Engine: Engine Cylinder Heads, Gas Engine Parts

 

  • Body & Chassis Components: Stator, Brackets, Electronic Covers, Shades Pole, Stepping motor, Wheel hub coupling

 

  • Safety Parts: Auto Fork, Heat Sinks, Starter Motor Bracket, Wiper Bracket

 

Our industry is top-rated in manufacturing these parts, and we produce thousands of high-quality automotive parts each day.

The following are some top products of Aluminum die casting marine and ship parts.

  • Maritime Satellite Communication: Satellite dishes, Radio assembly for satellite systems

 

  • GPS positioning system: Cell Tower components, TV outlet cover, Frame for 2-way radio

 

  • Hunting Underwater system: ROV, Headlamp parts, Speargun parts, Sea hunter parts, Metal detector gadget parts

 

The above are just a few examples; our industry is capable of producing every type of simple-to-simple and complex-to-complex parts.

 

The following are some top products of aluminum die-casting telecommunication parts.

  • Radar & Frequency control system: Flywheel, Tower Crane Panel parts

 

  • Antenna: Pyramidal horn, Dipole parts, Helical parts

 

  • Transmitter: One tube transmitter switch, Power supply filters, Tubes

 

The following are some top products of aluminum die-casting Instrumentations & General industry parts.

  • Ultrasonic Scanner: LEDs, Printer parts, CPU parts, Disk Storage parts, Keyboard parts

 

  • Flow control system: Converter parts, Stem parts, bonnet parts, Pressure regulator cover/switches, body parts

 

  • Textile Industry: Heaters & boilers parts, Burner parts, Engraving machinery parts, Heating chamber parts, and many more

 

  • Home applicants & IT: Housing for air blower, Bracket for stepping motor, Feed roller, Solenoid Valve, Sidewall

 

 

WHAT ARE THE ALUMINUM DIE CASTING BENEFITS FOR TELECOMMUNICATIONS?

 

When designing your telecommunication connector, device, or some other parts, consider Aluminum die casting as your process of choice.

When you partner with our industry, then you can receive the following benefits from our side:

  1. Complex net shapes manufacturing
  2. High level of quality over high volumes
  • Cost-effective and high-level volume production
  1. Tight tolerance achieved as-cast
  2. Cast housing is highly durable
  3. Integration of heat-sinks within production designs
  • Fully recyclable
  • Wide variety of finishes from high-specification plating
  1. Value engineering
  2. Minimal draft angles on internal-features
  3. Thin-wall technology for devices

 

IS THERE ANY FINISHING OPERATION ON PRODUCTS AFTER ALUMINUM DIE CASTING?

 

So, the answer is yes! And now, the question is, what are the post-processes or finishing operations after Aluminum die casting?

To produce a shiny & reliable quality part, the following steps are essential to follow on an aluminum die-casted part.

  • Heat Treatment: This process improves the mechanical and physical properties of the Aluminum die-casted parts.

 

 

The process of heat treating consists of heating and cooling of die casted part.

 

This process does not change or affect the shape of the part just and only improve it ultimately.

 

  • CNC Machining: Computer Numeric Control Machining, it is used for automation of machine tools using computer programmed commands.

 

Our industry uses CNC machining as an after-process to finish aluminum die casting.

 

 

But it mostly depends upon which parts require CNC machining and which one doesn’t.

 

We apply CNC machining on parts where tight tolerances or finish is required.

 

 

  • Laser Cutting: Some complex parts require laser treatment on Aluminum die-casted parts.

 

 

These specific parts then cut by laser for quality and durability purposes. The laser-cut the aluminum die-cast part at 250 watts.

 

Afterward, a laser marking spray is used to leave a dark mark on the surface of the aluminum part.

 

 

  • E-Coating & Passivation: This process is applied mostly based on the chemical properties of Aluminum die-casted products.

 

It is a process of treating or coating an aluminum metal to reduce the chemical reactivity of its surface.

 

E-Coating is known as electrodeposition coating, which is a method of painting.

 

This process works according to the principle of “opposites attract.” It uses electrical current to deposited paint on a surface.

 

  • Assembly: Finally, the parts are ready to be assembled.

 

 

In this process, the quality and standards of products measured and chosen the perfect ones, and the other proceed to back-process from the start.

 

WHAT IS ALUMINUM DIE CASTING vs CNC MACHINING?

 

Why our industry prefers using Aluminum die casting over CNC machining? Quite a simple answer because die casting comes down to cost and speed.

Die Casting also handles complex parts easier as compared to CNC machining.

CNC machining wastes a lot of Aluminum during the process of production, while Aluminum die-casting uses a perfect amount of Aluminum.

Aluminum die-casting also is a near-net-shape process. This process is fast and repeatable.

Those were some critical points according to which aluminum die casting is preferred over CNC machining.

 

WHAT ARE THE ASSEMBLY METHODS FOR ALUMINUM DIE-CASTED PRODUCTS?

 

Aluminum die casting is a popular and well-known manufacturing process. The Aluminum die-casted parts are of high quality.

They can require a minimal number of secondary processes in some cases. There are few methods to assemble individual aluminum die-casted parts.

 

These methods include:

  • Adhesive bonding

 

 

  • Attachment systems

 

  • Prevention of external threads

 

  • Forming or self-cutting fasteners

 

  • IMA (Injected Metal Assembly)

 

 

  • Inserts

 

  • Interference fits

 

  • Threaded fasteners

 

WHAT ARE THE BENEFITS OF THE FASTER PRODUCTION CYCLE OF ALUMINUM DIE CASTING?

 

The fast production cycle is mostly the primary focus for some clients and industries because it can save you time & money both.

The faster production time significantly reduces the time for large batch production: A vital consideration as your clients insist on rapid production.

Aluminum Die Casting can be used to produce complex shapes very quickly and correctly.

And when they come out of the die, afterward, minimal CNC machining is required. This process further reduces manufacturing times if there are simple shapes.

Quantity matters and you can cast large complex parts easily through die-casting Aluminum.

Every industry adopting the lightweight production and for this die casting is becoming even more relevant.

The geometry of the lightening features is also created with-in the casting cycle.

A quickly wound up of benefits of the fast production cycle:

Save time

Save cost

  • Rapid Production

Produce complex shapes quickly & perfectly

Lightweight production

Afterward, minimal CNC machining is required

 

WHAT TO NOTICE WHEN BUYING AN ALUMINUM DIE CASTING PRODUCT?

 

Always prefer buying or manufacturing your products from one-step Aluminum die casting solutions because only these industries are experts of die-casting Aluminum and never compromise on quality.

Most importantly, check if the seller has the quality ISO and IATF certifications.

See if they have QC standards;

  • ISO9001:2015
  • IATF16949:2016

 

WHAT ARE THE WEIGHT LIMITATIONS OF ALUMINUM DIE CASTING PRODUCTS?

 

The maximum weight limitations for aluminum casting is approximately 70 pounds or 32 kg.

The material used for Aluminum Die Casting defines minimal section thickness & minimum draft required to run the die-casting process.

The standard weight of Aluminum per minimal quality possible is 0.098 lb./cu. In.

The production rate of the most massive Aluminum die casting parts is 40-60 shots/hr.

Detail dimensions and weight limitations of aluminum alloys:

  • Maximum weight: 70 lb.
  • Minimum wall thickness: 0.80 large castings, in.
  • Minimum wall thickness: 0.040 small castings, in.
  • Minimum variation per in. of diameter or length from drawing dimensions over one in.: 0.0015
  • Cast threads: 24 max. Per in. external
  • Cored holes: 0.080 min. Diameter in.

 

HOW ALUMINUM DIE CASTING PROCESS HANDLES COMPLEX SHAPES?

 

It all depends upon the tooling. A suitable cavity is selected according to the complexity of the part.

Industries prefer Aluminum die casting for the production of complex parts. Because of its high-speed production within closer tolerances than other mass production processes.

After complex products die-casted, there is no need required for additional after-process tooling.

Complex shapes can be designed and produced with a high degree of accuracy and repeatability.

The aluminum alloy also considered the best fusion in the production of complex parts because it produces lightweight and high dimensional stability parts.

 

 

WHAT IS POROSITY IN ALUMINUM DIE CASTING PRODUCTS?

 

Porosity is a big concern in die casting, and it means that there is some kind of significant defect in the material you’re working with.

Sometimes porosity is vital to meet your stability and structural integrity requirements.

Porosity can be mostly found in void-outs, meaning if there is a small void, hole, or pockets of air within the material.

Porosity occurs when the air is trapped into the metal by the die casting machinery, or the product isn’t pressed perfectly.

It often leaves gaps at the top of the die filling the cavity slowly and having some solidification occur at early stages.

One more reason for its accordance is when the air used to force molten Aluminum into the cavity isn’t forced out utterly.

 

HOW TO IDENTIFY THE CAUSES OF POROSITY IN ALUMINUM DIE CASTING?

 

The most common and accurate way to check for porosity in aluminum products is an X-ray of the material. By using a software computerized “tomography.”

Or can be checked by cutting and polishing a section and then analyzing it under a microscope.

 

Following can be some causes of porosity in Aluminum die casting:

  • The design of the mold and Aluminum die casting part
  • The purity of the aluminum alloy is used
  • Pressure and the injection shot speed of the die casting machine
  • Shrinkage of the material wall thickness
  • Presence of too much lubricant in the die
  • Mold sharp corners
  • Low aluminum temperatures
  • Air trapped in the metal

 

WHAT ARE THE POROSITY PREVENTION METHODS FOR ALUMINUM DIE CASTING?

 

Aluminum die-casting porosity varies in severity. However, sometimes it is acceptable, but mostly it is best to limit it as much as possible.

The most suitable procedures to control the porosity are following:

  • work to create an efficient and accurate process for die casting.

 

Also, remember ensuring the aluminum alloys you are working with is the high-quality and perfect selection for the specific product. Process monitoring must focus on equipment/tool maintenance & stability. Which helps guarantee an even and adequate amount of pressure throughout the Aluminum die casting.

 

  • Gas porosity is the name of a natural fenomina and that is “The formation of air bubbles inside of a die-casting.”

 

And it can be avoided by melting the Aluminum in a vacuum or a low solubility gas environment.

Gas porosity occurs because of a natural phenomenon that liquids can hold dissolved gases.

In some cases, this can be addressed by exposing the melted Aluminum to another gas.

This way, these two gases react and pull each other out of the liquid.

 

  • One of the significant causes of porosity can be oxide formation.

 

If that occurs, then your aluminum alloy will also benefit from being degassed adequately after melting or filtered before using the Aluminum for making the casting.

 

  • Due to cooling problems, two significant defects can take place, hot tears, and hot spots.

 

If one of them occurs, you must make sure that your aluminum casting is cooled enough.

If hot spots persist, you need to adjust the cooling practices by Aluminum die spray. Or further cooling it with an addition of extra cooling channels.

 

 

WHAT IS THE MINIMUM POROSITY OF ALUMINUM DIE CASTING?

 

There is not a static number that defines the minimum porosity of Aluminum dies casting, but there is a method of measuring it and helps to ensure the quality of outgoing products and the performance of die-casting processes.

Traditional laboratory methods, such as hot extraction, is used but can be too expensive and slow.

Thanks to technology, the Reduced Pressure Test (RPT) is often used.

It is a semi-quantitative method with limited accuracy and provides an indication of porosity level in aluminum alloys.

 

WHAT DOES IT MEAN BY HYDROGEN GAS POROSITY IN ALUMINUM DIE CASTING?

 

It’s a general and most occurring type of gas porosity in aluminum alloys.

It’s an aluminum die casting defect in the form of a gas porosity or a void-out in aluminum casting, and it is caused by a high level of hydrogen gas.

Hydrogen gas dissolves in the aluminum alloy at its liquid phase.

But the fact is the solubility of hydrogen in solid aluminum alloys is much smaller than in liquid aluminum alloys.

As the Aluminum starts to freeze, some of the hydrogen gas comes out of the solution and forms into bubbles. And end up with creating porosity in the solid Aluminum.

Industries try to produce high-quality Aluminum die casting with minimum porosity.

And it can be reduced by minimizing/reducing the amount of hydrogen gas in the liquid aluminum alloy. And it can be possible by degassing or sparging.

 

HOW CAN ALUMINUM ALLOYS BE PROTECTED FROM HYDROGEN PROBLEM IN DIE CASTING?

 

If molten Aluminum came into the contact with the water vapor, then the hydrogen gas forms naturally and dissolves itself into the melt.

Afterward, when the melt solidifies, hydrogen gas tends to come out of the solution and forms bubbles on the aluminum product’s surface.

Controlling the excess of dissolved hydrogen in the Aluminum can be a good start for preventing it from happening.

There are two main methods used for the protection of aluminum alloys from hydrogen gas.

  • Furnace fluxing before the casting process
  • Using in-line degassing equipment during the die casting process

Our industry used them both according to our needs and produced a royal-quality high-end product.

 

WHAT ARE THE APPLICATIONS OF ALUMINUM DIE CASTING?

 

The following are some critical applications of Aluminum Die Casting:

  • Aluminum Die Casting contribution to weight-saving requirements; it improves automotive fuel efficiency.
  • Aluminum Die-Cast parts used in broad-range networking & infrastructure equipment in the telecom and computing industries.
  • Aluminum Die Casting provides EMI/RFI shielding, rigidity, and durability in smart devices and also minimizes the weight of them.
  • Aluminum Die Casting is ideal for electronic connectors and housing because of its operating ability, even in high-temperature environments. And of its excellent electrical performance and shielding properties.

 

HOW DOES RECYCLING WORK IN THE ALUMINUM DIE CASTING PROCESS?

 

Did you know that over 90% of Aluminum that is die-casted in China is made of post-consumer recycled Aluminum?

When it comes to die-casting Aluminum, there is a miner functional difference between primary and secondary (recycled) Aluminum.

The secondary Aluminum produced from mixing and melting pure Aluminum with other materials like magnesium or copper etc.

The use of pure Aluminum by industries in die casting is infrequent because of its high price.

The lightweight and durability of aluminum alloys make them a top choice for customers and manufacturers.

It is more economical to produce secondary Aluminum than primary because it only requires 5% of the energy to produce.

During fabrication, most of the energy consumption in Aluminum die casting is used to heat up and re-melt the metal.

Our industry also saves more time, energy, and money by re-melting recycled Aluminum.

 

Are you interested in more about how to design optimal aluminum die casting components?

Here is the ultimate design guide for aluminum die casting parts from Sunrise Metal.

 

 

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