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Die Cast Metal Products and Aluminium Die Casting Companies
Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. Molten metal is forced into these dies under high pressure and held until it solidifies. The process is highly efficient for producing large volumes of small, intricately detailed metal parts with tight tolerances.
Die cast parts are made from non-ferrous metals that can be melted and poured into dies. The most common die cast metals are zinc, aluminum, magnesium, copper, and tin-based alloys. Of these, zinc and aluminum are used in the majority of die casting applications.
Advantages of Die Casting
There are several key advantages that make die casting a popular choice for metal part manufacturing:
- High production rates: Die casting is extremely fast, capable of producing hundreds or even thousands of castings per hour per die. This leads to lower part costs through economy of scale.
- Excellent dimensional consistency: Die cast parts can be produced with tight dimensional tolerances and smooth, detailed surface finishes. This reduces or eliminates secondary machining operations.
- Complex geometries: Die casting can produce intricate shapes with thin walls, dimensional stability, and excellent repeatability. Parts have an excellent surface finish right out of the die.
- Wide choice of alloys: A broad range of metal alloys are available for die casting depending on part requirements, from durable zinc alloys to lightweight magnesium and aluminum.
- Lower costs for high volumes: Though the initial die tooling is expensive, once the dies are made, the per-part cost of each casting is very low for high production runs. This makes die casting ideal for large volume production.
Aluminium Die Casting
Aluminum is one of the most popular alloys used in die casting. Aluminum parts can be made with great precision and at low per-part cost for large production runs. Aluminum die castings provide an excellent strength-to-weight ratio. They have high dimensional stability for complex geometries and thin walls.
Advantages of aluminum die cast parts:
- Lightweight yet strong: Aluminum die castings are lightweight while maintaining excellent tensile strength. This makes them suitable for parts that need to be light yet durable.
- Heat resistance: Aluminum die castings retain strength and integrity at relatively high operating temperatures. This allows their use in parts exposed to heat like automotive engine components.
- Corrosion resistance: Aluminum naturally develops an oxide film that protects against corrosion. This makes aluminum die castings ideal for use in outdoor applications or exposed to weathering.
- Electrical and thermal conductivity: Aluminum is an excellent conductor of heat and electricity. This allows aluminum die cast parts to be used where heat dissipation or electrical conductivity is needed.
- Dimensional stability: Aluminum castings hold tight tolerances even with complex, thin-walled part geometries. This reduces secondary machining.
- Appearance: Aluminum die castings can have an attractive bright chrome-like finished surface when polished or protected by anodizing.
Applications of Aluminium Die Cast Parts
Aluminum die casting is used across a vast range of industries to produce high volume, cost-effective and durable aluminum parts. Typical applications include:
- Automotive: Engine components like manifolds, oil pans, valve and timing chain covers are commonly die cast from aluminum alloys. Other auto parts like steering knuckles, dashboards, and transmission cases are also frequently die cast.
- Aerospace: Aluminum die casting is used to make complex aircraft fittings and components that require high strength-to-weight ratios. These include parts like hydraulic manifolds, flight control components, engine mounts, and wing attachments.
- Electronics: Aluminum die casting provides excellent electrical conductivity for electronics parts needing heat dissipation like enclosures, covers, frames, and shields. Aluminum is also used for computing components like laptop hinges and handles.
- Appliances: Aluminum die casting is ideal for appliances needing corrosion resistance, strength and lightweight. Parts include oven door handles, control panels, ventilation fan housings, and display screens.
- Medical Devices: Aluminum's corrosion resistance, lightweight and biocompatibility make it suitable for parts like MRI scanner components, medical carts, operating theatre lights, and medical tools.
- Recreation: Aluminum die castings are used to make intricate components for sporting goods like golf club heads, tennis rackets, and bicycle frames and components like derailleurs.
Aluminium Die Casting Process
While there are variations, aluminum die casting primarily relies on two main processes: hot chamber die casting and cold chamber die casting.
- Hot Chamber Die Casting: This involves melting the aluminum alloy inside the die casting machine and injecting it directly into the dies at high pressure. The molten aluminum is held in a bath inside the machine, keeping the liquid at ideal pouring temperatures. Hot chamber die casting allows for very high production rates of simple, thin walled aluminum parts.
- Cold Chamber Die Casting: With cold chamber die casting, the aluminum alloy is melted in a separate furnace outside the die casting machine. The molten metal is periodically ladled out and poured into an unheated shot chamber, then injected into the dies under pressure. Cold chamber die casting is used for heavier, thicker castings and alloys that are hard to melt like silicon-aluminum. Production rates are lower than hot chamber processes.
For both hot and cold aluminum die casting, the general process steps are similar:
1. Molten aluminum starts in the furnace/bath (hot chamber) or is ladled into the shot chamber (cold chamber).
2. The two die halves close and lock together. The injection piston advances, forcing molten aluminum into the die cavity under high pressure (around 25,000 psi).
3. Pressure is held momentarily to compress any trapped gases and force metal into every detail of the die surface.
4. The injection cylinder retracts. As the aluminum cools and solidifies, the casting separates from the movable half of the die.
5. The die halves open and an automatic ejection system separates the casting from the fixed die half, allowing it to fall free into a bin.
6. After spray lubrication, the die halves close again and the cycle repeats at high speed, yielding hundreds of castings per hour.
The entire process takes place in seconds, with castings rapidly cooling as heat transfers into the steel dies. Modern die casting machines are highly automated using robotics and computer control for optimal efficiency, speed, precision and repeatability.
Aluminium Die Casting Companies
Many companies specialize in aluminium die casting services. When looking for an aluminum die casting supplier, important factors to consider include:
- Experience: Look for established companies with many years of experience in aluminum die casting services. They should have expertise across a wide range of industries, applications, and aluminum alloys.
- Capacity: Choose a company able to meet your production volume needs. Larger suppliers have numerous die casting machines and facilities to handle high volume production.
- Quality Systems: The company should follow strict quality control standards and procedures during the entire aluminium die casting process. ISO 9001 certification is ideal.
- Secondary Operations: Many die casters offer additional services like CNC machining, surface treatments like anodizing and plating, custom packaging & assembly. This simplifies the manufacturing process.
- Tooling Design: For creating new die cast parts, partner with a company that can design and rapidly prototype the casting and dies. Quick tooling turnover lowers costs.
- Customer Service: Look for responsive customer service focused on meeting delivery commitments and providing engineering support. Reliable on-time delivery is crucial.
When designed properly, aluminum die cast parts can provide outstanding performance. Partnering with an experienced die caster minimizes risk and provides access to the tightest tolerances, latest alloys, and most sophisticated die casting technologies available. With an expert aluminium die casting company, you benefit from their full knowledge and process capabilities. CNC Milling CNC Machining