What is Aluminum Die Casting? Intro, Applications, Pros…

aluminum auto die casting

Die casting injects molten metal under high pressure. High speed can make thin-walled parts with complex shapes, and the obtained casting has a fine grain, dense organization and high strength. The productivity of die-casting is high, so die-casting is widely used in automobiles, computers, communication filters, medical equipment and other manufacturing industries, such as central control instrument panels, motor cases, steering systems, laptop shells, double cavity filters and other parts.

As a lightweight metal, the most common reason for using aluminum die casting parts is that it allows very light parts to be made without sacrificing strength.

This article will help you to understand the basics of the die casting aluminum process. Let us understand more about aluminum die casting.

 

Table of Contents

What is aluminum die casting?

Aluminum die casting is a kind of pressure casting part, is the use of pressure casting machinery die casting machine loaded with casting moulds, heated into the liquid aluminum or aluminum alloy into the feed port of the die casting machine, casting out the shape and size of the mould limit of aluminum parts or aluminum alloy parts, such parts are usually called aluminum die casting.

The aluminum die casting process is based on rapid production and allows for high speed and more cost effective production of large quantities of die cast parts compared to alternative casting processes.

What are the advantages of aluminum die casting?

(1) Can manufacture metal parts with complex shapes, well-defined contours, and thin-walled deep cavities. Because the molten metal is high pressure and speed to maintain high mobility, and therefore can obtain other process methods challenging to process metal parts.

(2) High dimensional accuracy of die casting, up to IT11-13, sometimes up to IT9, the surface roughness of Ra 0.8-3.2um, good interchangeability.

(3) High material utilization: Due to the high precision of die-casting, only a tiny amount of mechanical processing can be assembled and used. Some die-casting can be directly assembled and used. Its material utilization rate of about 60% – 80%, and the utilization rate of the blank is up to 90%.

(4) High production efficiency: Due to high-speed filling, filling time is short. The metal industry solidification is rapid, die-casting operation cycle speed. In various casting processes, die-casting method productivity is high and suitable for mass production.

(5) Convenient to use inlay parts. Easy to set the positioning mechanism on the die-casting mould, convenient to inlay casting parts.

6) 100% Recyclable and reusable.

What is the typical grade of die casting aluminum alloys?

Alloys Series

GB

China Standard

ANSI

American National Standards Institute

SAE J452

American Society of Automotive Engineers

JIS

Japanese Industrial Standards

DIN

German Institute for Standardization

Al-Si-Mg

YL104

360

309

 

YL101

A360

309

ADC3

AlSi10Mg

Al-Si-Cu

YL112

A380

306

ADC10

AlSi8Cu3

 

YL113

A383

383

ADC12

 

A384

303

ADC12

Al-Si

YL102

A413

305

ADC1

AlSi12

 

C443

304

ADC7

Al-Mg

YL201

518

ADC5

AlMg9

A360 has excellent resistance to pressure and corrosion. In addition, they have excellent fluidity when molten. Suitable for  communication boxes, automotive controller housings, automotive oil pans, etc.

A380 alloy has excellent product and casting properties and is the most commonly used alloy for various products.

What are the applications of aluminum die casting?

Global Market Insights, Inc. forecasts that the global aluminum alloy market will exceed $150 billion by 2024, with continued demand for strong, durable, and lightweight materials in the construction and transportation industries.

Construction

Aluminium die casting parts are used in window frames, doors, hardware and more. 

Renewable Energy

In the renewable energy industry, the aluminium die casting process is used to produce a variety of parts. Examples include solar panel mounts, wind turbine parts and more. Also includes the new energy car industry.

Automotive

Aluminum alloys are lightweight and very useful in the automotive industry. Aluminium die casting parts are everywhere, from engines and drive systems to body parts.

Electronics

Aluminum has always played an essential role in producing these consumer products. 

DIECASTING PRODUCTS

What are the surface treatments for aluminum die casting products?

The surface treatment of aluminum die casting is generally: powder spraying, baking paint, oil spraying, oxidation, sandblasting, electroplating, etc.
Powder spraying:
Is to use powder spraying equipment to spray powder coating to the surface of die casting. Under electrostatic action, the powder will be uniformly adsorbed on the die casting surface, forming a powder coating. Powder coating after high-temperature baking levelling curing, into a powder coating of different kinds of effect; powder spraying effect in mechanical strength, adhesion, corrosion resistance, ageing resistance, etc., better than the spraying process, the cost is also lower some. Powder spraying is divided into outdoor powder and indoor powder. The pattern can be adjusted to various effects, like glossy, sand, foam, etc.

 

Spraying (paint, powder)

Baking process:
The Baking process uses aluminum phosphate spraying, spraying and then baking so that the coating is not only anti-corrosion and bright, wear-resistant, and not easy to fall off. Surface pretreatment: oil removal, washing, rust removal, washing, table conditioning, washing, phosphating, washing, washing and drying. The pretreatment of baking paint is to get a good coating because the above stamping parts will have grease, oxide rust, dust, rust and corrosion on the surface during manufacturing, processing, handling and preservation. If not removed will directly affect the performance of the coating film, appearance, etc., so the pretreatment occupies an important position in the coating process.

die casting Cigarette Sample Display

Anodic oxidation :

Aluminum oxidation treatment Anodic oxidation is putting aluminum parts into the electrolytic bath under the condition of electricity, and die casting is used as the anode to produce a layer of denser aluminum oxide film on the surface; although the anodic oxide film has good protection and wear resistance, its resistance is high and does not conduct electricity; the oxide film obtained from aluminum and aluminum alloy after the conductive oxidation process has electrical conductivity, which is its performance, and the film has good protection and decorative properties.

Electroplating treatment:
Electroplating is the process of using electrolysis to deposit metal or alloy on the surface of the workpiece to form a uniform, dense, well-bonded metal layer called electroplating. In simple understanding, it is a physical and chemical change or combination. In applying the electroplating process, we generally use anti-corrosion, protective decoration, and anti-wear. According to the thickness of the product surface treatment, the finish is different to carry out the corresponding surface treatment.

How to calculate the cost of aluminum die casting materials?

Material cost = material weight * material unit price – scrap weight * scrap unit price. 

Material weight = (product net weight + machining margin) * the number of cavities / (1 – burn rate) / process output rate, which involves machining margin, burn rate and process output rate, several vital parameters. The following we briefly explain.

Machining allowance, this is well understood. We all know that the die-casting out of the blank must be machined to become finished products (except precision die-casting). We get the technical information is generally finished products. You need to restore the blank to calculate the weight of the material. In general, the mounting surface needs to be machined. Here we generally think 2mm processing thickness can be. If there are holes, we generally think The holes below 10 diameters can not be obtained by core extraction but need to be machined. Through the above, you can get the weight of the blank before machining.

Burn rate, metal burn is the loss of metal materials in the melting process, generally related to the melting point of the metal, melting temperature, and melting equipment. Due to aluminum oxidation and aluminum and furnace wall, the melting process of aluminium alloy, refining agent interaction and non-recoverable metal loss is called burnout, burnout and slag metal contained in the total called melt loss. Here in the industry, generally default 5%.

Process output rate refers to the loss of aluminum water into the mold and finally into the finished product, which includes the loss of the sprue, sprue system, discharge system, residual material and other parts. Generally speaking, the die-casting process output rate is according to the weight and complexity of the product, generally in 40%-60%, the specific situation One By One.

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