What is LED Die Casting?

Aluminum Die Casting for LED Lighting Industry

Die casting has proven to be an effective method to produce different parts components in different materials: copper, zinc and aluminum alloys. The die casting process ensures dimensional accuracy and the finished product requires little or no machining, which in turn is economically viable. The various properties of aluminum make it a good metal for die casting.

Properties of aluminum for the lighting industry

Lightweight

Aluminum is a very light metal, about one-third the weight of steel, and this lightness also reduces noise. However, this lightness does not affect the strength of the metal in any way, as this can be achieved by changing the composition of its alloys.

Good thermal conductivity

Aluminum has excellent thermal conductivity, three times that of steel, a property that makes it an important material for cooling and heating applications, including heat sinks for LED lights and computer motherboards.

High electrical conductivity

Aluminum has a very high electrical conductivity, enough to be used as an electrical conductor, which is why it is the preferred choice for most electrical transmission lines.

Recyclability

Aluminum is 100% recyclable and recycled the same as the original product, making it a more cost effective source of production material.

Non-corrosive (ideal for outdoor use)

Aluminum has a naturally protective thin oxide coating that helps prevent the metal from coming into contact with the environment when exposed to air.

Some different die-casting methods for manufacturing aluminum LED luminaires

Gravity casting or permanent mold casting

Gravity casting or permanent mold casting is a process very similar to aluminum die casting, except that some of the changes are the use of light metals in the East. The process uses a reusable mold made of metal and uses gravity to fill the mold. However, in some cases, the die casting machine may use vacuum or air pressure.

Liquid Forging

Liquid forging is a hybrid of casting and forging processes and is a good choice when high integrity is required. An example is the manufacture of heat sinks for LED lamps. In this process, a fixed amount of molten metal is poured into a cavity and extruded under pressure while the metal solidifies in the cavity. The advantage of this process is that the components can be manufactured in a single process.

Is it better to have a die-cast aluminum housing or a car aluminum housing for LED luminaires?

 Die-cast aluminum housings and car aluminum housings use different aluminum raw materials. Die-cast aluminum housings are usually made of raw aluminum, while automotive housings are usually made of cooked aluminum. Raw aluminum (sanding aluminum) is a natural refining chemical composition – aluminum oxide extracted from the purity of aluminum, the internal composition contains a certain amount of silicon elements, high hardness and easy to brittle. Cooked aluminum has high purity, light and thin, good ductility, and because of the hardness is not high, easy to use lathe cutting processing, but easy to deformation. The price of cooked aluminum is higher than raw aluminum, so if it is used to make bulky die-casting shell, the cost will be very high.

 The main differences between raw and cooked aluminum are

Cooked aluminum purity: 98% or more aluminum, soft nature, can be calendered or punched and rolled many kinds of utensils. Raw aluminum purity: below 98% aluminum, the nature of brittle and hard, can only turn sand casting products. So most aluminum alloy die-casting, including LED lamps and lanterns die-casting shell are using raw aluminum, because raw aluminum is only suitable for making die-casting, and high hardness, low cost.

 

 In addition, die-casting LED lamps and lanterns shells in mass production but very advantageous, because the generation of die-casting fast, low production costs.

The CNC lathe cutting processing of aluminum housing abbreviated as car aluminum  

  LED lamp car aluminum shell generally choose aluminum alloy 6063-T5, its thermal conductivity of about 180-190W / M.K, the power of some LED lamps and lanterns shell are using this process, car aluminum can be done more exquisite, thick and thin is easy to control, so that the heat dissipation surface area will increase, enhancing the heat dissipation effect, the advantage is that the heat dissipation effect is significantly better than die-casting But the production speed is slow and the cost is much higher than die-casting.

Currently Pingtan LED lamps and lanterns die-casting zinc aluminum alloy shell thermal conductivity of about 80-90W/M.K, coupled with subsidiary oxidation residue, as well as surface oil spray or electroplating and other processing, the actual thermal conductivity is a little worse. If you use aluminum alloy AA1070 to cast LED lamps and lanterns heat sink, die-casting fins are very thick, which results in a small heat dissipation area, but also not conducive to heat dissipation.

Car aluminum material for aluminum alloy 6063-T5, its excellent thermal conductivity of about 180-190W / M.K, heat sink fins can be made very thin, only 1 mm, a unique thermal structure design, the maximum increase in heat dissipation area, so that the product at room temperature for a long time, the cup temperature can be maintained below 50 ℃, thus effectively reducing the use of LED process The light decay, more guarantee the quality of the lamps. According to actual measurements, the same size of the LED ceiling lamp radiator, the car aluminum sunflower radiator heat dissipation effect than die-casting aluminum shell by more than one-third.

Die-casting can be made into a variety of appearance shapes, a variety of shapes, low cost, but the appearance will be relatively rough and not delicate, general heat dissipation. Car aluminum appearance of high-grade and exquisite, good heat dissipation, but the price is high.

Die-cast aluminum can be used for different applications in the LED lighting industry, such as

Heat sink parts housings

Lightweight parts housings

Coolers

Aluminum die casting services are used in several leading markets. We meet our customers’ needs for high quality requirements, including radiator housings, light frame housings, and coolers. We take great pride in our ability to reduce manufacturing and machining costs.

Contact us today for more information and to learn how we can save you time and money in manufacturing components.

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