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Aluminum Die Casting

Views:2     Author:Site Editor     Publish Time: 2020-04-22      Origin:Site


Aluminum - This alloy is lightweight, while possessing high dimensional stability for complex shapes and thin walls. Aluminum has good corrosion resistance and mechanical properties, high thermal and electrical conductivity, as well as strength at high temperatures.

Aluminum die casting machine

Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die.

 

Aluminum die casting is a process where molten aluminum alloy is injected into a casting die under high pressure and at a controlled temperature. The mold has two sections, the "cover" half and the "ejector" half. The die may also have additional moveable segments called slides or pulls, which are used to create features such as undercuts or holes, which are parallel to the parting line.

Aluminum die castings dies are run in cold chamber die casting machines. These machines are operated at the required temperatures and pressures to produce a quality part to net-shape or near net-shape specifications. Aluminum die castings can be readily machined, anodized, painted, powder coated or even chrome plated.

Because of its superior mechanical properties, aluminum die castings are among the highest volume, mass produced items manufactured by the metalworking industry today.

Aluminum die castings are important components of products like automobiles, computers, washers, dryers, refrigerators, furnaces and even toys. Some parts can be as simple as a faucet handle or as complex as a transmission housing.


The castings that are created in this process can vary greatly in size and weight, One common application of die cast parts are housings - thin-walled enclosures, often requiring many ribs and bosses on the interior. Metal housings for a variety of appliances and equipment are often die cast. Some automobile components are also manufactured using die casting, including pistons, cylinder heads, and engine blocks, turbocharging system parts, belt tensioner parts, emissions system parts, fan clutch parts. Other common die cast parts include automatic equipment and machine, gear housing of power tool, blade low (upper) guards of power tool, flange of power tool, cutting saw bracket, CCTV camera body (housing), covers of motorcycle motor, lamp body, lamp housing, lamp brackets, lamp radiator, lamp cover, cotton thread speed disc, feed cotton thread disc, cotton thread storage wheel, support seat for cotton thread storage wheel, motor housing of textile machine,housing for solar energy equipment, propellers,gears,bushings, pumps,valves, bathroom products and furniture appliances and office appliances.


Product Applications for Aluminum die casting alloys


Aluminium alloy die casting application detail :

Item

Typical

Feasible

Shapes:

Thin-walled: Complex
Solid: Cylindrical
Solid: Cubic
Solid: Complex

Flat
Thin-walled: Cylindrical
Thin-walled: Cubic

Part size:

Weight: 5g - 6000g

Materials:

Aluminum


Surface finish-Ra

3.2 - 6.3 µm

1.6 - 12.5 µm

Tolerance:

±0.10mm.

±0.05-0.50mm.

Max wall thickness:

2- 20mm.

1- 35mm

Advantages:

Can produce large parts
Can form complex shapes
High strength parts
Very good surface finish and accuracy
High production rate
Low labor cost
Scrap can be recycled

Disadvantages:

Trimming is required
High tooling and equipment cost
Limited die life
Long lead time

Applications:

Engine components, pump components, appliance housing, etc.


Aluminum alloys properties :

Aluminum alloy properties

Low density

Good corrosion resistance

High thermal and electrical conductivity

High dimensional stability

Relatively easy to cast

Requires use of a cold chamber machine


Common types of aluminum alloys:

Alloy 380 is the most common of the aluminum die casting alloys in North American and Europe. It offers the best combination of casting and product properties. It is used for a wide variety of products such as garden equipment, chassis for electronic equipment, engine brackets, housings for automotive alternators, starters and water pumps, home appliances, furniture, office equipment hand tools and power tools.

Alloys 383 and 384 are alternatives to 380 that are specified when very intricate components require improved die filling characteristics and improved resistance to hot cracking.

Alloy 360 offers high corrosion resistance and superior strength at elevated temperatures than 380. Other properties are essentially equivalent.

Alloy 413 offers the best die fill characteristics making it excellent for pressure tightness applications. It is the choice for products such as hydraulic cylinders and pressure vessels. Its casting characteristics make it useful for very intricate components.

Alloy 390 was developed for automotive engine blocks. Resistance to wear is excellent, but ductility is the lowest of the die casting alloys, with elongation less than 1%. Special surface treatment systems allow engine pistons to run directly on the alloy surface, eliminating the need for ferrous alloy liners. It can also be used for valve bodies and bearing surfaces subject to abrasion and wear.  

Alloy 518 is used in escalator components, conveyer components, and marine and aircraft applications It offers good ductility, and very good corrosion resistance. It can be polished and anodized for a decorative finish.

 

Alloy ADC12 is also the most common of the aluminum die casting alloys in China and Japan. It also offers the best combination of casting and product properties.


ADC12 aluminium alloy chemical composition (%) (JISH2118:2006)


Element

Cu

Mg

Si

Fe

Mn

Ni

Zn

Pb

Sn

Ti

Cr

Al

Standard

(%)

1.5-

3.5

0.30Max

9.6-

12.0

0.6-1.0

0.50Max

0.50 Max

1.0Max

0.2Max

0.2Max

0.3Max

0

balance


ADC12 aluminium alloy mechanical property (GB/T 13822-2017)


Mechanical property

Tensile strength σb /MPa

Yield strength σ0.2 /MPa

Extensibility δ5 /%

Standard

280

150

2.0




Founded in 2008, Pinter Die Casting Factory, and it is renamed Ningbo Pinter Machinery Technology Co., Ltd. in 2015; It is the professional manufacturer in designing and making of die casting which is applied in Aluminum and Zinc alloy. Our products are widely used in automotive, motorcycle, power tool, lamp, textile machine and household industry. We do business all over the world, and our main partners are BOSCH, SIEMENS, POLARIS, HARLEY-DAVIDSON, PHILIPS, OPTIMAS, LR-TEK, CHIIPS, GREELY etc.    View More >>

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