Guide to The Aluminum Die Casting process

 

At Creatingway, we use aluminum die-casting to produce precise and complex aluminum parts. All of these done within a very short period. Parts that range from automobile parts e.g. car disks and pump elements come from this method. It involves pushing molten aluminum into reusable steel molds to easily make the parts. Also, the method offers more benefits when compared to limitations that will be discussed later.

Here Is Further Insight Into The Process Itself

Steps to Aluminum Die Casting

Aluminum has qualities great for casting. Such as a low melting point, good mold filling rate, and fewer chances of cavity formation. We thus recognize its great potential in making a variety of aluminum cast parts. The process starts by first pouring molten aluminum into a cavity. We do this under great pressure to ensure no cavity forms. After completely filling the cavity, we let it solidify by cooling. This allows for the later ejection of the finished part. Lastly, we unclamp the steel dies ready to begin forming a new aluminum case.

We use coating inside the steel molds to ensure a longer tool life. The special coatings include chromium, iron oxides, or talc suspension. It functions to either raise or lower heat exchange between the casting and dies. It also eases the ejection step of the process. This gives aluminum die casting its reusable ability.

Types of Aluminum Die Casting

There are two main types of this process. These are high-pressure die casting and low pressure die casting. Here is a review of the main differences between the two.

• High-Pressure Die Casting

The high-pressure die casting injects liquid aluminum rapidly inside water-cooled dies. We use a shot chamber and a hydraulic ram to ensure this rapid injection. The difference lies in how long we maintain pressure until ejection. It is from the start of injection to the end of ejection. First, it allows for faster part production. Secondly, the grain structure of the aluminum alloy remains small. This enables the achievement of a finer tensile property.

• Low-Pressure Die Casting

The low pressure dies casting has a unique structure. The set up consists of a suspended die over the molten filled tank. In the riser system, we direct a pipe beginning from the bottom-placed die towards the center of the tank. We then put pressure on the tank to force the molten aluminum up the pipe. This fills the cavity found between the dies. After solidification of the cast, we release the pressure. In the non-riser system, we do not use a pipe. We however enclose the entire system inside a vacuum chamber. The cavity thus has a negative pressure to allow metal flow during the injection process. This type of die casting reduces the chances of getting undesired additions in the molten aluminum. Although it needs stronger dies for the set-up, thus increasing cost.

What’re The Types of Dies?

• Combination die that produces a different part for later assembly.
• Multiple cavities that produce many similar parts.
• A single cavity that produces one component.
• Unit die that produces different many different parts at one time.

What’re The Benefits of Aluminum Die Casting?

• Accuracy and Stability

Aluminum die casting produces dimensionally accurate and stable parts. It also does this while maintaining close tolerances.

• Fast Production Rate

The process can produce one single part without the need for welding or any post joint processing. Therefore, it lessens the production time skipping this step. It also produces near-identical parts in the thousands. You are thus sure of getting products that function the same without any additional tooling.

• Multiple Finishing Options

The range of finishing choices are many. It ranges from smooth texture to textures one. All of these happens with only little surface preparation for the aluminum part.

• Good Quality and Strength

Aluminum die-cast parts are stronger than other casting parts of similar dimensions. Also, it is much lighter due to its ability to make thin-wall castings. Additionally, the extra weight does not come from welded and fastened parts as the parts are not separated. Therefore, it keeps structural integrity.

• Simpler Assembly Requirements

We can easily integrate fastening elements into the aluminum die casting parts. Features such as studs and bosses or holes can be cast during the process. This will later make it easier to assemble once the casting is complete.

What’re The Applications of The Aluminum Die Casting?

• Cabinets for the electrical industry
• General hardware appliances such as plumbing part and pump parts
• Kitchenware e.g. pressure cookers
• Bicycle parts
• Automotive parts e.g. wheels, manifolds, and cylinder heads
• Aerospace castings

You need to hire an experienced and proficient company for your die casting needs. Our dedicated team assures you strong, light, and top-quality pressure die casted products. Contact Creatingway now for your aluminum die casting services.

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