All you need to know about Aluminum Die Casting?

aluminum-die-casting

July 19, 2022

When you are in the process of designing an Aluminum part, it is essential to consider what manufacturing process you will use to manufacture it. There are several methods of forming aluminum, and High-Pressure Aluminum Die Casting is one of the most common options designers should consider

What is High-Pressure Die Casting? The procedure is explained.

High-Pressure Aluminum Die Casting (HPDC) is a highly efficient production process for manufacturing various product shapes. The method of forcing molten metal into a closed steel cavity in a mold at high speed and pressure. The Die has a fixed half and a movable half; both are mounted on the platens of the casting molding machine. The die casting machine has injection tips that use hydraulics and pressurized gasses to move a piston forward and inject the molten metal into a sealed steel mold. High-Pressure Aluminum Die Casting has an exciting loop that uses hydraulics and mechanical switches to take injection pressure and keep the mold closed as the part solidifies. In seconds, the process can turn molten metal into solid parts with an almost net-like shape.

The 4 Steps of High-Pressure Die Casting

High-Pressure Aluminum Die Casting, also known as traditional die casting, is a metal casting process that involves the injection of molten metal—steel, zinc, copper, aluminum, tin, magnesium, and more. - in a three-dimensional matrix. The base metal is heated until it reaches a molten state and is then fed into the mold cavity, allowing it to take on the shape of the mold after cooling.

High-Pressure Aluminum Die Casting makes everything from engine blocks to aerospace components to heavy-duty fasteners. While there are various options, most high-pressure die casting processes consist of the following four steps.

  1. Mold preparation: The first step in high-pressure die casting is mold preparation. In this first step, a high-pressure die casting parts manufacturer applies a lubricant to the inner walls of the mold. This is important because the oil regulates the temperature of the mold while creating a thin layer between the molten metal and the mold, making the Casting easier to remove.

  2. Injection: After preparing the matrix, the manufacturer injects it with molten metal. The form must be completed, closed, and sealed at this step. Otherwise, it cannot "accept" molten metal under high pressure. Depending on the application, the molten metal can be injected into the mold at pressures ranging from 1,500 to 25,000 pounds per square inch (PSI). The mold maintains this pressure until the molten metal cools and hardens.

  3. Remove the cavity: The manufacturing company removes the newly created cavity from the mold. The High-Pressure Aluminum Die Casting itself usually includes an ejector pin which, when gripped, releases the cavity. Of course, the cavity must be rigid for it to be removed. If the raw metal is still molten, the manufacturer must wait for it to cool before removing the cavity from the mold.

  4. Shakeout: The fourth and final step of High-Pressure Aluminum Die Casting is shaking. The production company separates each scrap metal from the newly created cavity in this step. It is not uncommon for excess metal residue to be produced during high-pressure die casting. In other words, not all molten metal is used to make castings, and some will stick to the mold. As a result, scrap metal must be removed before the matrix can be reused.

What are the Advantages of Aluminum casting?

Design

High-Pressure Aluminum Die Casting can come in any size, shape, configuration, or shape you can imagine. From the minor electrical components weighing less than a gram to transmission housings and automatic clutch housings, High pressure Die casting parts manufacturers every part precisely to design requirements, defect-free, and with minimal post-processing requirements. The advent of a High-Pressure Aluminum Die Casting has allowed engineers to create all kinds of configurations with the confidence that the part will perform as expected. Cast Aluminum components maintain integrity through assembly, disassembly, repair, and remanufacturing.

Versatility

A wide range of possible design factors allows engineers to take advantage of the outstanding properties of cast aluminum. The versatility of High-Pressure Aluminum Die Casting enables the flexibility to dream up all kinds of custom creations, no matter how unique or unusual, and makes it possible to make them happen.

Production Speed

High-pressure Die casting parts manufacturers constantly look for faster and more efficient ways to produce high-quality products. Computerization has increased the pressure to deliver on time to meet customer demands. As increased efficiency and productivity demand increases, High-Pressure Aluminum Die Casting is more than capable of meeting and exceeding demand. Parts, components, and parts are manufactured faster than other types of alloys.

Strength

One of the most outstanding properties of High-Pressure Aluminum Die Casting is its strength-to-weight ratio, which surpasses any other metal or alloy. Aluminum products are light but have the strength of steel, which contributes to their durability and longevity, an essential factor for 21st-century products.

Appearance

Although High-Pressure Aluminum Die Castings are solid and light, they have a positive appearance and aesthetic value. There are several uses for cast Aluminum that don't require it to be visible or to have a pleasing appearance. In applications where you want them to be presented and attractive, they don't need to be customized or reworked.

Cost

Every industry is looking for tools and methods to reduce costs and produce high-quality products. The low cost of the High-Pressure Aluminum Die Casting process is an essential factor that drives companies to choose it for product development. Most of the cost savings are due to the speed of production and the elimination of the need to complete the finished product. Lower material costs, faster production cycles, and elimination of rework are passed on to customers and consumers.

Corrosion Resistance

When High-Pressure Aluminum Die Castings are exposed to air, their surface is oxidized, a metal property. This factor is why Aluminum castings are durable and reliable; this extended lifespan gives consumers more value.

Conclusion

High-Pressure Aluminum Die Castings is a highly viable, low-cost, and high-precision casting process for the mass production of complex parts. The choice of material and casting process depends on the desired design features; therefore, one should consider all aspects and plan effectively to achieve optimal results.

We hope you find this article valuable. Arbomex's professional High-Pressure Aluminum Die Castings service ensures you get the right part of your design. Armed with decades of machining and design experience and state-of-the-art production facilities, we have everything we need to deliver high-quality products for almost any customer's needs. Contact us today to learn more about our high-pressure die casting parts capabilities or discuss your Die casting needs with one of our experts.