Aluminum Die Casting

Aluminum Die Casting is one of the common casting processes to create cast aluminum components, which uses die casting technique with aluminum alloys that are both lightweight and strong. Due to this quality, it has quickly become popular as part of die casting processes. Also through die casting, it can produce even complex designs for various uses and purposes.

CFS Foundry specializes in aluminum die casting. Offering value-added services such as CNC machining and surface finishing, we can be your one-stop source for all cast aluminum items.

An Overview of Aluminum Die Casting

Die casting is specifically suitable for producing thin wall or complex aluminum components. Aluminum ingots are heated at high temperatures until they become completely liquidized before being cast out into molds for molding into finished parts.

Aluminum liquid is then injected under pressure into a casting mold (composed of two halves). Once solidification takes place in this steel mold, solid cast aluminum parts form and will eventually be removed.

Die cast aluminum parts usually require minimal or no further processing, as they have a smooth surface and good size accuracy out-of-the-mold, and steel molds can often be reused several times before wear sets in. With its economical cost structure and ability to produce many parts quickly at high volumes, aluminum die casting makes an excellent solution for high volume production of aluminum parts.

Aluminum Die Casting Process

The aluminum die casting process is an intricate process involving numerous steps, including mold design, mold fabrication, melting and alloying, die casting, and post-processing. Here’s a brief overview of each step:

Step 1: Mold Design

Like investment casting, the aluminum die casting process also requires a pair of molds to produce parts successfully. So, the design of the mold is the first step to start the aluminum die casting process. The die cast mold consists of two halves, which cavity is the exact shape of the desired cast part. The mold design takes into consideration factors such as part geometry, draft angles, gating and venting, and the material properties of the aluminum alloy.

It is worth to mention that the mold cost of aluminum die casting parts is always high. This is because the mold material is tool steel, which has a high material cost. Besides, the mold sizes are also large. And due to the complex shape of die cast aluminum parts, the machining cost of the mold is also high. So, aluminum die casting is less effective for small production runs. We suggest a medium to high production run to invest in the mold cost.

Step 2: Mold Manufacturing

Once a design for the mold has been finalized, the creation of the mold involves several processes including CNC machining, wire EDM and grinding. Each step must be carried out with extreme precision to guarantee that its final part meets the desired specifications. CFS Foundry offers in-house mold design & manufacturing capabilities which help save both cost and manufacturing time. The mold to guarantee the quality, the approval of an initial sample is necessary before mass production.

Step 3: Melting and Alloying

The next step is to melt the aluminum alloy in a furnace. Here, its composition must be precisely controlled to achieve the desired mechanical properties and chemical compositions. Alloying elements such as magnesium, silicon and copper may be added to enhance the alloy’s strength, ductility, and corrosion resistance. At CFS Foundry, we always test each element of the alloy using an optical spectrum instrument, and the material report will be provided before delivery.

Step 4: Injection

Once aluminum alloy has been heated to a liquid state, it is then injected under high pressure using either a plunger or piston into a mold cavity, so as to to ensure complete filling of mold cavities and rapid solidification of metals. The solid aluminum part is then ejected from the mold using ejector pins. The ejection mark is always seen on the surface of each casting piece, but can be removed by grinding.

Step 5: Post-processing

After the part is ejected from the mold, depending on each item’s surface finishing requirement, it undergoes post-processing steps such as trimming, deburring, polishing, or other surface finishing processes. These steps are essential to remove excess material or imperfections from the part and achieve the desired surface finish. CFS Foundry can also provide CNC machining services to deliver finished machined parts if needed.

Step 6: Quality Control

Quality inspection is same important as the die casting manufacturing. It is avoidless there may exist quality issues during the production process, even if the part is very simple. So the dimensions, chemical compositions and mechanical properties should be strictly inspected before delivery, and all the testing reports should be sent to the clients. CFS Foundry has been equipped with several testing instruments, such as spectrometer, hardness tester, CMM, etc, and we can meet different inspection requirements for our customers.

Aluminum Die Casting Advantages

Good Corrosion Resistance

When aluminum die castings are made, these parts are exposed to air and moisture, which creates an oxide layer that protects the surface from extreme oxidation. This oxide layer projects aluminum castings against deterioration, weathering, and industrial atmospheres that promote weathering. For special die cast aluminum parts with higher corrosion resistance requirements, we can further improve its surface quality by machining, powder coating, anodization, and more.

Strength

Aluminum alloys possess exceptional tensile strengths that make them cost-effective solutions in many industries. Die casting can help increase their strength similarly to forging techniques; additionally, we may add other elements like copper, manganese or silicon for further strengthening purposes. Please keep in mind that die cast aluminum parts cannot be heated treated; hence heat treatment would not increase their strength effectively.

High Strength-to-weight Ratio

Die cast aluminum alloys have superior strength-to-weight ratios compared to cast steel or iron, making them more desirable when designing and manufacturing strong yet lightweight aluminum casting parts for various industries.

Compared to cast steel or cast iron, die cast aluminum alloys have a better strength-to-weight ratio. Due to this property, aluminum alloys are preferred for designing and manufacturing strong and lightweight die casting parts for various industries.

Easy for Mass Production

The process of aluminum die-casting starts with the mold to produce parts within specific tolerances and shapes. Additionally, aluminum die casting requires minimal or no machining, and can mass produce thousands or tens of thousands of parts without incurring significant machining costs. Therefore, aluminum die casting is an efficient manufacturing method capable of mass producing aluminum parts at competitive costs.

Dimensional Stability and Strength

Die-cast aluminum parts are highly reliable and dimensionally stable with tight tolerances, offering years of use without issues or failure.

Common Aluminum Die Casting Alloys

Aluminum Die Casting Alloys

Aluminum die casting alloys differ from pure aluminum in that they incorporate other elements such as silicon, copper, magnesium, iron manganese and zinc. Common alloy types for die casting at our foundry include A360, A380, and A383 alloys.

Aluminum alloy A360: This alloy offers exceptional corrosion resistance and strength even at higher temperatures; good flexibility, pressure tightness and fluidity properties – but can be relatively challenging to cast.

Aluminum alloy A380:  It is one of the most frequently used die cast aluminum alloys because of its excellent mechanical properties, such as outstanding flowability, lightweight corrosion resistance, compressive strength at elevated temperatures, and electrical conductivity. These features make this alloy popular with toolmakers, frame builders and automotive engine producers alike. A380 alloys also serve an array of other uses, including electronics, communications engines, automotive engines, gearboxes, furniture appliances, etc.

Aluminum alloy A383 (ADC12): Although less commonly employed, A383 could serve as an economical and viable alternative to A380 for intricate components.

When choosing the best aluminum die casting alloy for your business, you need to know its differences. A380 is usually chosen, while A383 could also work depending on your part designs, which require special performance during die casting.

Castings made with A383 alloys are less durable than A380. A360 is more difficult to cast than A380. Therefore, it is necessary to check the properties of the alloys when considering an aluminum alloy.

Design Considerations of Aluminum Die Casting

Design Considerations of Aluminum Die Casting

Design considerations must be made when using aluminum die casting technology for creating parts.

First and foremost, the mold must be designed so that solidified aluminum parts can easily be taken out from its casting process. The line dividing up the two halves of the mold – known as its parting line – should be taken into account during mold design.

Consideration must also be given to the location of injection points. If the molten metal solidifies before reaching the mold gap, it is better to design the casting with multiple injection points. This method is advantageous if the design has cavities; you can enclose them with aluminum, and the part can still be detached when the mold is separated.

The pat’s wall thickness must also be taken into account. Thanks to recent technological developments, there are usually no guidelines for a minimum wall thickness, but walls of uniform thickness would be better.

How Aluminum Die Casting Differs From Other Processes

Aluminum Die Casting vs. Aluminum Gravity Casting

Aluminum gravity casting (also referred to as permanent mold casting) differs significantly from aluminum die casting in terms of how molten metal enters its mold. In aluminum gravity die casting, it is poured directly into the cavity under gravity. while for the aluminum die casting process, it must enter under pressure (from 1500-25.4400 PSI). This pressure is maintained until the casting solidifies.

Aluminum die casting is preferred when working with thinner and more complex shapes in bulk if the tooling cost is high while the casting cost is low. In comparison, aluminum gravity casting is preferred to produce hundreds or thousands of pieces for its low tooling cost.

Aluminum Die Casting vs. Aluminum Sand Casting

Aluminum die casting involves injecting liquid aluminum under high pressure into an intricate mold to produce complex parts with tight tolerances that meet mass production standards. Sand casting, on the other hand, utilizes molds made out of sand instead of die casting to achieve shape creation. Aluminum die casting is more versatile for complex parts due to higher dimensional accuracy in large production runs.

Aluminum Die Casting vs. Aluminum Forging

Aluminum die casting produces more complex shapes with tighter tolerances, thinner walls, and reduced finishing costs.  Cast core holes are not possible with aluminum forging.  Aluminum forging is expensive as the die casting tools of aluminum forging tools are expensive because they do not have to absorb as many shocks during the casting process. Moreover, aluminum die casting is far more efficient and allows the production of multiple copies of identical parts in a short time.

Aluminum Die Casting Applications

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CFS Foundry is dedicated to providing die casting solutions with aluminum alloys for various industries. We aim to help our customers deliver products that exceed quality requirements. We have maintained our reputation as a leading manufacturer of aluminum die castings serving a variety of industries, including:

Commercial and Industrial Equipment: We offer our valuable services in this industry to provide compressor pistons and connecting rods, heat sinks, bearing housings, and many more specific parts with the help of aluminum die casting.

Electrical: We also offer aluminum die casting for electrical housings, including LED modules and cell tower equipment.

Firearms: We are also helping the firearms departments by offering them the right parts for rifles and shotguns. Moreover, we are also providing them with aluminum die-cast trigger guards and receivers.

Lighting: CFS foundry also provides LED lights and other light products along with aluminum die cast heat sinks and other related components.

Medical Devices and Products: As an aluminum die casting company, we primarily work for the medical department, including ultrasound systems, drug dispensers, heart monitors, and bed gearboxes.

Meters: Our aluminum die casting services are also available for electric, water, gas, parking, and other meters.

Recreational Vehicles: Parts developed through vacuum aluminum die casting for recreational vehicles, plus lawn and garden tractors.

Small Engines: Now, you can also get small engine parts and accessory design and development from China’s most experienced and leading aluminum die casting company.

Automotive Parts: Our specialization includes automotive parts and systems, from cylinders and gladhands to transfer cases.

CFS’ Capabilities of Aluminum Die Casting

CFS Foundry is not limited to aluminum die casting but offers a wide range of services. Our company is committed to providing you with a one-stop solution for your project. Whether it’s rapid prototyping or high-quality surface finishing, we’ll be happy to help you get finished products in one go without any hassle.

Die Casting Tooling

Our cutting-edge in-house mold shop lets us offer complete solutions, such as mold design, manufacturing, modification, maintenance, and final mold management. CFS has been working for years, and you will see our expertise in your final product and the quality of the mold. Although our rapid depends on your volume and requirements, we usually deliver the products within only 2-4 weeks or less.

We have advanced equipment and machinery, allowing us to provide top-class mold and tooling manufacturing services.

Aluminum Die Casting Production

Aluminum Die Casting Workshop

At CFS Foundry, we have the most advanced machines, from 280T to 2,500T, which enable us to provide our customers with high-quality parts. Having years of experience, advanced machinery, and a wide range of materials, we can assure you that we will meet your product requirements.

We have been proudly serving our worldwide customers for more than 20 years, and every time we make sure that we deliver the highest quality parts to our customers. We always take responsibility for the quality of our products. This is why CFS Foundry is the leading die casting brand in China.

CNC Machining

CNC Machining for Aluminum Die Castings

Our die casting foundry is equipped with 24 CNC machining centers and 5 CNC lathes to meet our customers’ requirements. This enables us to machine not only die casting parts but also solid, extrusion, gravity casting, forging, etc. Thanks to our advanced technology and experienced staff, we can provide you with precise and high-accuracy CNC machining service according to your requirements.

Surface Finishing

Surface Finishing of Aluminum Die Castings

We strive to provide our customers with a one-stop solution; that’s why we are providing a wide range of services with various high-quality surface finishing options that will increase the worth of your final products.

Our services include:

  • Shot Blasting • Powder Coating • Liquid Painting • Electroless Nickel
  • Anodization  • Mirror Polishing • Pad Screening

Contact CFS Foundry for Aluminum Die Casting Services

Contact CFS Foundry for Your Aluminum Die Casting Project

CFS Foundry has been the top aluminum foundry for aluminum die casting manufacturing for two decades, producing high-quality die castings to serve various industries ranging from automotive and aerospace, to electronics. Our state-of-the-art facilities and advanced technologies enable us to provide custom solutions specifically for you. Working closely with each client, we understand their specific requirements, so we deliver products that surpass all their expectations.

At CFS Foundry, we understand the significance of timely delivery and high quality guarantee. Our team of specialists ensures that your project is finished on schedule and within budget. Our quality control procedures guarantee every part produced meets our high quality standards, and advanced techniques & equipment monitor each stage from design through production until delivery. Besides aluminum die casting, we also specialize in CNC machining, surface finishing and assembly – providing one-stop-shop solutions for all of your manufacturing requirements.

Are You Needing Aluminum Die Casting Services? Contact CFS Foundry today to discover our services and request a free quote!