Aluminum Die Casting

Aluminum Die Casting is one of aluminum casting processes using die casting technique with aluminum alloys. If you are seeking high-quality aluminum die casting supplier for your project, look no further because CFS Foundry is the best aluminum foundry to choose, with value-added services like surface finishing, CNC machining, and more.

Since aluminum alloys are lightweight yet strong, they have become a popular choice for the die casting process. Through the process of aluminium die casting, it can be supplied in even more complex designs for a variety of applications.

What is Aluminum Die Casting?

The process is specially designed for complex aluminum parts production. Aluminum ingots are heated at high temperatures until they are entirely molten.

The aluminum is now liquid and is injected into a steel mold known as a casting mold (consists of 2 halves) under very high pressure. Once the molten aluminum solidifies in the mold, the solid cast aluminum parts form, which will be taken out from the mold.

The finished die cast aluminum parts usually requires no or minimal machining as it already has a smooth surface and good size accuracy. These steel molds can be used multiple times before wearing out. These features makes aluminum die casting ideal for high-volume production of aluminum parts.

Aluminum Die Casting Process

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

Mold design: The first step in the aluminum die casting process is mold design. A mold is a tool that is used to produce the desired shape and size of the part or component. The mold design takes into consideration factors such as part geometry, draft angles, gating and venting, and the material properties of the aluminum alloy.

Mold fabrication: Once the mold design is finalized, the mold is fabricated using a variety of techniques such as CNC machining, wire EDM, and grinding. The mold must be made with high precision and accuracy to ensure that the final part meets the desired specifications.

Melting and alloying: The next step is to melt the aluminum alloy in a furnace. The alloy composition is carefully controlled to achieve the desired mechanical properties and chemical composition. Alloying elements such as magnesium, silicon, and copper are added to improve the strength, ductility, and corrosion resistance of the alloy.

Die casting: Once the aluminum alloy is molten, it is injected into the mold cavity under high pressure using a plunger or piston. The high pressure ensures that the molten metal fills the mold cavity completely and solidifies quickly. The part is then ejected from the mold using ejector pins.

Post-processing: After the part is ejected from the mold, it undergoes several post-processing steps such as trimming, deburring, polishing, and surface finishing. These steps are essential to remove any excess material or imperfections from the part and achieve the desired surface finish.

Aluminum Die Casting Advantages

Aluminum die casting is the best choice for manufacturing aluminum parts because it offers countless advantages over other metal forming processes, such as:

Corrosion resistance
When aluminum die castings are manufactured, these parts are exposed to air and moisture, which creates an oxide layer that protects the surface from extreme oxidation. This self-protection guards aluminum parts against deterioration, weathering, and industrial atmospheres that promote weathering. We can further improve the resistance by treating the parts with anodizing.

Aluminum alloys used in the industry have high tensile strength, making them affordable and valuable for various industries. Further processing methods, such as aluminum die casting, increase the strength even more. Moreover, we can further increase the strength of the alloys by mixing them with various elements such as copper, manganese, and silicon.

High strength-to-weight ratio
Compared to steel casting alloys, aluminum die casting alloys have a better strength-to-weight ratio. Due to this property, aluminum alloys are preferred for designing and manufacturing strong and lightweight parts for various industries such as automotive, lighting, marine, etc.

Easy for mass production
The process of aluminum die-casting starts with the mold to produce parts within specific tolerances and shapes. In addition, little or no machining is required, and can produce thousands or tens of thousands of parts. So it is pretty easy to implement mass production.

Dimensional stability and strength
Parts made from die-cast aluminum are highly durable and dimensionally stable, with tight tolerances. They are also heat resistant.

Common Aluminum Die Casting Alloys

Aluminum Die Casting Alloys

Different from pure aluminum , aluminum die casting alloys always mix other elements: silicon, copper, magnesium, iron, manganese, and zinc. Common aluminum die casting alloys are Alloy A380, Alloy A383, Alloy A360.

Aluminum alloy A360: This alloy offers high corrosion resistance, superior strength even at high temperatures, and good flexibility; they also have excellent pressure tightness and high fluidity, but these alloys are relatively challenging to cast.

Aluminum alloy A380: It is the most common type of aluminum die casting because it offers exceptional properties and easy fabrication. Its properties include excellent flowability, lightweight, corrosion, hot cracking resistance, compressive strength, dimensional stability, high strength at elevated temperatures, and high electrical conductivity. They are widely used for tools, frames, electronics, communications equipment, automotive engines, etc. Aluminum A380 alloys are also frequently used in gears and gearboxes, furniture, appliances, and other industries. Alloy A380 also has above-average machining properties.

Aluminum alloy A383 (ADC12): While not commonly used, it can be used as an alternative to A380 for intricate components. It exhibits excellent mechanical properties and improved die casting characteristics.

When choosing the best aluminum die casting alloy for your business, you need to know their differences. The most commonly used alloy in aluminum die casting is A380, but you can also use A383 as an alternative if you are working with complicated die-cast parts that require special die casting performance.

Castings made with A383 alloys are not as durable as 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

Things must be taken into account when designing a part with aluminum die casting process.

First of all, the mold must be designed so that the solidified aluminum part can be easily removed from the casting. The line splitting the mold into two halves is called the parting line and must be considered in the early stages of mold design.

It is also necessary to consider the location of the 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 Compare with Other Processes

Aluminum Die Casting vs. Aluminum Gravity Casting

The main difference between aluminum gravity die casting (also called permanent mold casting) and aluminum die casting is how the molten metal enters the mold. The molten metal is poured into the mold in aluminum gravity die casting and fills the cavity under gravity. In the aluminum die casting process, the molten metal is injected into the mold under pressure (between 1500 and 25,400 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. While 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 produces parts with thinner walls, closer dimensional limits and smoother surfaces.  Production is faster and labor costs per casting are lower.  Finishing costs are also less for aluminum die casting, however the tooling cost of aluminum die casting is higher than that of sand casting. Aluminum sand casting is widely used to cast automotive engine blocks and pistons, bushings and bearings, aluminum furniture, as well as hydraulic and pneumatic components. Aluminum die casting, on the other hand, excels at making intricate machine and automotive parts, small toys, medical devices, and electrical and electronic components.

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 the identical part 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 majorly work for the medical department, including ultrasound systems, drug dispensers, heart monitors, bed gearboxes, etc.

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 one of the most experienced and leading aluminum die casting companies.

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 not only to machine die casting parts but also to machine 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 Your Aluminum Die Casting Project

Contact CFS Foundry for Your Aluminum Die Casting Project

CFS Foundry is a leading aluminum die casting company with over 20 years of experience in the industry. We specialize in producing high-quality aluminum die castings for various industries, including automotive, aerospace, electronics, and more. Our state-of-the-art facilities and advanced technologies allow us to provide customized solutions that meet your specific needs. We work closely with our clients to understand their requirements and ensure that the final product meets their expectations.

At CFS Foundry, we understand the importance of timely delivery and cost-effective solutions. Our team of experts ensures that your project is completed on time and within budget. We take pride in our quality control procedures, which ensure that every part produced is of the highest quality. And we use advanced techniques & equipment to monitor every stage of the production process, from design to delivery.

In addition to aluminum die casting, we also offer other services, including CNC machining, surface finishing, and assembly. This makes us a one-stop-shop for all your manufacturing needs.

So, if you’re looking for a reliable partner for your aluminum die casting project, look no further than CFS Foundry. Contact us today to learn more about our services and how we can help you achieve your manufacturing goals.