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Aluminum die casting is the process of forcing molten aluminum metal under high pressure into a mold. This mold is constructed of two machined steel parts known as a die. The die casting process is very similar to injection molding and allows for mass production of aluminum parts with complex shapes within very close tolerances.
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Aluminum Die Casting Advantages
Because the steel dies used to manufacture die cast parts are reusable, aluminum die casting offers the primary advantage of mass production of the most complex parts with identical characteristics. The die creation process of die casting, as well as the equipment required, is costly, making aluminum die casting suitable (and even ideal) only for parts being produced in high volumes. Aluminum die casting is typically accomplished in massive cold chamber die cast machines, which can range from 250 to 1,200 tons. Aluminum die cast parts can weight anywhere from a few ounces to nearly 30 pounds. In addition to the die cast machines, the aluminum die casting process also requires trim presses to finish the die cast parts, which themselves range from 20 to 250 tons. Die casting produces a very good surface finish and dimensional consistency. Die cast parts can be complex and sharply defined and can be manufactured with either smooth or textured surfaces with many different finishing options.
Characteristics of Aluminum in Die Casting
Aluminum in various alloys has grown to become the preferred metal used in die casting due to its numerous inherent advantaged. Aluminum die castings are lightweight yet have great strength for their weight and aluminum offers excellent corrosion resistance, making it ideal for parts that come into contact with moisture or water (including, for example, sink faucets). Aluminum has the highest operating temperatures of all the possible die casting alloys, and is often used for heat dissipation, conductivity, and EMI shielding. Aluminum die castings maintain their high strength even at high temperatures and also maintain their high dimensional stability. Aluminum has a high thermal and electrical conductivity. Depending on which aluminum alloy is used, aluminum has a tensile strength of as much as 47,000 pounds per square inch and a yield strength of up to 36,000 pounds per square inch. The lower end melting range of the most common aluminum alloys is 970 degrees F.
