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The Ultimate Guide to Aluminum Die Casting

March 15, 2022

What Is Aluminum Die Casting?

Aluminum die casting alloys are lightweight and possess high dimensional stability for complex part geometries and thin walls. Aluminum withstands good corrosion resistance and mechanical properties as well as high thermal and electrical conductivity, making it a good alloy for die casting. Low-density aluminum metals are essential to the die casting industry. The Aluminum Die Casting process retains a durable strength at very high temperatures, requiring the use of cold chamber machines. The molten metal is still contained in an open holding pot which is placed into a furnace, where it is melted to the necessary temperature. The open holding pot is kept separate from the die casting machine and the molten metal is ladled from the pot for each casting because these high temperatures would damage the normal pumping system. The pressure requirements for cold chamber castings are typically higher than those of hot chamber die castings.

  • A manufacturing process that produces accurately, defined, smooth and textured-surfaced metal parts

  • Accomplished by forcing molten metals into a mold form due to high-pressure systems

  • Corrosion resistant

  • Highly conductive

  • Have a good stiffness and strength-to-weight ratio

  • Based on rapid production

  • Allows a high volume of die casting parts to be produced very quickly

  • Is more cost-effective than alternative casting processes

The Ultimate Guide to Aluminum Die Casting

Aluminum Die Casting Auto Oil Pan

The Aluminum Die Casting Process

The casting process implements a steel mold often capable of producing tens of thousands of castings in rapid succession. The die must be made in at least two sections to permit removal of castings. The casting cycle begins with the two die halves are clamped tightly together by the die casting press. Molten aluminum is injected into the die cavity where it solidifies quickly. These sections are mounted securely in a machine and are arranged so that one is stationary while the other is moveable. The die halves are drawn apart and the casting is ejected. Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting. Most machines use mechanisms actuated by hydraulic cylinders to achieve locking. Others use direct acting hydraulic pressure. Die casting machines, large or small, very fundamentally only in the method used to inject molten metal into the die.


What Are The Advantages of Aluminum Die Casting?

There are many reasons aluminum is the most commonly cast non-ferrous metal in the world. As a lightweight metal, the most popular reason for utilizing aluminum die casting is that it creates very lightweight parts without sacrificing strength. Aluminum die cast parts also have more surface finishing options and can withstand higher operating temperatures than other non-ferrous materials. Aluminum die cast parts are corrosion resistant, highly conductive, have a good stiffness and strength-to-weight ratio. The aluminum die casting process is based on rapid production that allows a high volume of die casting parts to be produced very quickly and more cost-effectively than alternative casting processes. Aluminum die casting has become the favored option for buyers worldwide. Characteristics and Advantages of Aluminum Die Castings include:

  • Lightweight and Durable

  • Good Strength-to-Weight Ratio

  • Great Resistance to Corrosion

  • Excellent Electrical Conductivity

  • Fully Recyclable and Reusable in Production

Aluminum die casting light cover

History of Die Casting Manufacturing

The history of Die Casting began in the early 1800’s, with the first die casting equipment being used for the Printing Industry. This technological advancement at the time was beneficial for the purpose of creating a mobile product. During the year of 1849, Sturges earned a patent for the invention of the first small hand manually operated machine designed for casting printing type. These unique Die Castings were designed in order to manufacture a variety of simple to complex shapes while possessing a high level of accuracy, creativity, and a persistent process in order to earn value for the products. In the later years of 1855, Otto Mergenthaler developed the linotype machine that became very popular and efficient piece of equipment used in the publishing industry.

A great demand in the production of commercial die casting grew in the early 19th century due to the growth of the high volume of production in various industries. This movement opened up many different markets for the Die Casting Industry to expand into many diverse operations. During this innovation period, Aluminum and Zinc Die Casting Production took over the initial metals of Tin and Lead due to the higher quality features obtained by these products. The original process of low-pressure injection die casting has changed to the high-pressure casting method as a result of modernized surface finishing and efficient production factors. Throughout history, all major products have been manufactured through die casting processes and have focused on saving companies a great deal of money in production. Consumers can rely on consistent results, durable lifespans, and reliably finished castings for their commercial and industrial needs depending on the demand. Grand View Research has declared that the Die Casting Industry is the largest process segment in the market accounting for 49.7% of global shares in 2016 fiscal year because of low-cost production rates and consistency.

Aluminum Die Casting Product Segmentation

The popularity of aluminum has expanded to many applications around the world today, driving competitive market shares primarily for its distinctive features such as lightweight; corrosion resistance, high electrical and thermal conductivity, high stability for complex shapes and high tensile strength. The transportation sector is the largest end-use segment for this industry. The increasing emission laws by the government regulatory authorities, along with consumer demand for a higher fuel-efficient vehicle is developing a necessity for aluminum casting. An example of increased operations for the industry includes the replacement of iron and steel components in a vehicle with lightweight high-quality aluminum in order to increase the fuel efficiency. The Aluminum die cast product is ideal for electronic connectors and housings die to its excellent electrical performance and shielding properties, even in high-temperature environments.

Another sector regarding the aluminum die casting demand includes building and construction in developing economies particularly in the Asia Pacific region. Aluminum Die Casting is associated with the creation of products including windows, cladding, curtain walling, prefabricated buildings, shop partitions, and fittings. Also, aluminum die casting products are used in aerospace operations or airplanes all around the world. The aerospace industry wants to produce a more dense and larger quality product at lower costs for these air-frame components as aircraft continue to grow in size along with population rates.

According to Transparency Market Research, the Asia Pacific region accounts for over the half the share in the global market for aluminum castings. In the years ahead, the region is expected to further increase its share by pulling in the maximum Compound Annual Growth Rate of 5.3% during the forecast period between 2017 and 2025, and the powerhouse of China taking most of the credit. This market region is expected to become US $22.67 bn by 2025. Another important driving force includes the regions of Europe and North America in the global market for aluminum castings. While Europe is expected to register a Compound Annual Growth Rate of 5.1% during the forecast period to become worth US $9.45 bn, and the North America regions is expected to rise at a Compound Annual Growth Rate of 4.9% to become worth US $4.22 bn by the end of the year 2025. The statistics provided in this article express the importance in future Aluminum Die Casting growth for global production needs.


How Is Aluminum Die Casting Applied Today?

Aluminum die casting is considered as a non expendable technique which can be repeatedly used to produce different shapes, sizes and thickness of die cast aluminum. The die casting process can produce variety of shapes with accuracy and attractiveness.

Aluminum die casting is now considered as an industrial procedure for the purpose of creating aluminum for sale or made as part of machines or any other commercial or industrial production. This is now the easiest process since aluminum is melted in the designated molds to produce the desired size, shape and thickness. This process is essential in creating metal parts with specified details and quality.

Aluminum Die Casting Telecommunication HousingIn aluminum die casting process, metals are molten in the cavities of steel molds using high pressure technique. Aluminum die casting can be done in a single or multiple cavities, unit die or a combination of dies depending on what is to be produced.

Before, aluminum die casting is done using a low pressure injection. However, recently die casting using high pressure is common as it can squeeze die cast aluminum to the desires sizes and shapes.

To produce smooth casting, the metal that is molted is injected under both high pressure and speed. The high pressure is maintained until the metal becomes solid. Once it is hardened, the die cast is opened for the purpose of removing the metal casted.

Aluminum manufacturers used many variations to produce the specified results. They can use any of the following: squeeze casting or semi solid molding. In squeeze molding, the molten metal is cast without any gas entrapment or turbulence using high pressure for the purpose of achieving the high quality results, dense as well as the treatable components of the materials. On the other hand, in semi solid molding, the metal billets are being casted for the purpose of producing heat treatable aluminum castings with low consistency.

With the advent of modern technology, more sophisticated machines are now used to have consistent quality control. Either cold chamber or hot chamber methods can be used for aluminum die casting. Aluminum die casting is the biggest die casting technique used nowadays to produce commercial, consumer and industrial products salable in the markets today.

Aluminum die casting is proven as beneficial to industrial products. In this process, there are various modifications that can be made on the production. Manufacturers spend less cost and less time in the making of the produced aluminum which are more attractive to the eyes of the buyers.

Aluminum die casting can totally eliminate post machining and repeated molding. This process is very economical and finished products made under this process are accurate and long lasting.

The Ultimate Guide to Aluminum Die Casting