Aluminum die casting is the method of choice for many automotive, industrial, and telecommunications products.  It is also frequently employed in the production of electrical, hydraulic, and lighting components.

For more information on the aluminum alloy die casting process, as well as assistance in determining if it is the best option for your application, you've come to the right place.

The Benefits of Aluminum (No.  1)die casting aluminum Casting is a type of casting that uses a die to cast the metal.
Aluminum alloy die casting has a number of advantages over other metal-forming processes, which may make it the best option for producing your aluminum parts.

 The production of complex automotive parts such as transmissions and engine blocks, for example, is a prime example of this.  The complexity and tight tolerances required for these products cannot be consistently achieved through other processes.  In addition, it is possible to have textured or smooth surfaces, and it has the ability to accommodate both large and small parts.

The Most Important Things to Consider When Designing a Part
 In cases where the molten metal would otherwise solidify before reaching every crevice of the die, it is possible to design the die with multiple injection points.  This can also be beneficial if the design includes cavities; you can surround the cavities with aluminum while still having the part come off when the mold is separated.

You must also consider the thickness of the walls of the component.  Because of recent technological advancements, there are typically no guidelines for the minimum wall thickness, but having walls of consistent thickness is often preferred.

 Green sand processes make use of wet sand to create the mold for the cast, which makes them less expensive than the other two processes.  The image above shows an operator pouring molten metal into a sand-casting mold.

The molten aluminum must be gravity poured into the mold, as opposed to die casting, which uses injection.  Permanent mold castings have the potential to produce casts that are stronger.

Die casting, on the other hand, provides better tolerances and better-finished surfaces than the other two methods, often eliminating the need for additional surface treatment after casting.

Machining and finishing options
Alternatively, a protective or decorative coating, such as a powder coat, can be applied to the finished part.  Other types of modifications, such as drilling and tapping, can be made to the parts after they have been cast.

The Most Common Aluminum Die Casting Alloys (Aluminum Die Casting Alloys)
Aluminum alloys such as A380, 383, B390, A413, A360, and CC401 are among the most commonly used in die casting.  The primary consideration when selecting an appropriate alloy is the application for which it will be used.

 B390 is used in applications such as automotive engine blocks because of its outstanding wear resistance and high hardness, despite the fact that it has the lowest ductility of any cast alloy.  In terms of casting and product properties, Alloy A380 is the ultimate jack-of-all-trades, providing a good combination of casting and product properties.  It is the most commonly specified alloy for casting a wide range of products.