Aluminium die casting is one of the most common processes to design aluminium parts. This method is widely used in automotive, industrial, and telecommunications products. It is also used in producing hydraulic, electrical, and lighting components.
Aluminium die-casting is the process in which molten aluminium is injected into the cavity of a die under higher pressure. After allowing it to get solidified you will get an aluminium component.
There are 5 important things to know about this custom aluminium die casting process.
Advantages of aluminium casting
Aluminium die casting process has many advantages over other metal-forming processes. One of the primary advantages is the ability to produce any complex structures. Transmissions and engine blocks are the perfect examples of complex parts that are produced by aluminium die casting process.
Consideration during part design
Mold must be designed with a parting line to easily separate and allow the solidified part to come out.
Design the die with multiple injection points to prevent early solidifies before reaching every sharp corner in the die.
Need consistency in the thickness of the part’s wall.
Comparing to other casting processes
Aluminium parts are also produced using green sand and a permanent mold process. Green sand process is less expensive comparing the other two which require only wet sand to create the mold.
No injection is required in permanent mold castings like die casting. Still, they are not offering better tolerances and finished surfaces like die casting.
Machining and finishing
It requires minimum machining and several options like sanding, sandblasting or orbital sanding can be used for surface finishing.
The shot-peening process is used in die casting to improve fatigue resistance.
The common aluminium alloys used in die casting are A380, 383, B390, A360, A413, and CC401.