Custom Online Aluminum Die Casting Service

Our **Custom Online Aluminum Die Casting Service** offers high-quality, precision-engineered aluminum parts tailored to your specifications. With quick turnaround times, we provide rapid prototyping, reliable production, and a variety of finishing options to meet diverse industrial needs.

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What Is Aluminum Die Casting?

Aluminum die casting is a manufacturing process where molten aluminum is injected into a steel mold under high pressure. It creates durable, complex, and precise parts used in various industries, including automotive, aerospace, and electronics.

Steps	Description
Mold Preparation	The high-strength steel mold is designed with intricate cavities. It is coated with a release agent to facilitate part removal and ensure a smooth surface.
Aluminum Alloy Melting	Aluminum alloy is heated to its molten state in a furnace at approximately 660°C. The molten aluminum is then transferred to the die casting machine for injection.
Aluminum Injection	Molten aluminum is injected into the mold under high pressure, typically 10,000-20,000 psi, ensuring that the alloy fills the mold cavities completely and precisely.
Cooling and Solidification	After injection, the aluminum rapidly cools and solidifies within the mold. The cooling rate depends on the part size and complexity, ensuring proper shape and strength.
Trimming and Finishing	Excess material, such as gates and runners, is removed from the casting. The part may undergo additional finishing, such as machining, sanding, or polishing for precision.

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Benefits of Aluminum Die Castings

Aluminum die castings offer numerous benefits, including high dimensional accuracy, lightweight yet durable parts, design flexibility for complex geometries, and cost-effectiveness for mass production. These advantages make aluminum die casting ideal for industries like automotive, aerospace, and electronics.

Benefits	Description
High Dimensional Accuracy	Aluminum die casting offers precise and consistent parts with tight tolerances and fine detail. This high accuracy reduces the need for post-processing and ensures the final product meets the design specifications.
Lightweight & Durable	Aluminum die casting produces lightweight parts that are strong and resistant to corrosion. This combination of lightness and durability makes it ideal for industries like automotive and aerospace, where performance matters.
Complex Geometries	Aluminum die casting can produce parts with complex geometries, intricate features, and thin walls. This allows for greater design flexibility and the production of parts that would be difficult or expensive to create using other methods.
Cost-Effective for Mass Production	The die casting process is highly efficient, making it a cost-effective choice for mass production. Its high speed and repeatability result in lower labor and material costs, ideal for high-volume manufacturing.

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Typical Casting Aluminum Alloy Available

We offer a range of high-quality aluminum alloys for die casting, including A356, A360, A380, ADC12 (A383), B390, A413, and anodized aluminum. Each alloy provides unique properties suited for various industries like automotive, aerospace, and electronics.

Aluminum	Aliases	Tensile Strength (MPa)	Yield Strength (MPa)	Fatigue Strength (MPa)	Elongation (%)	Hardness (HB)	Density (g/cm³)	Applications
A380	AlSi9Cu3 (EU), AC7A (Japan)	240-310	155-210	90-120	1-3	90-120	2.68-2.75	Automotive parts, industrial castings, housings
A356	AlSi7Mg (EU)	290-350	230-280	150-180	4-8	120-150	2.68-2.75	Aerospace, high-performance automotive, structural parts
A413	A383 (Japan)	240-310	150-200	85-110	2-4	85-115	2.68-2.75	Precision castings, thin-walled components
A360	AlSi9Cu3 (EU)	250-310	180-230	100-120	3-5	95-120	2.65-2.75	Automotive, industrial components, pressure die casting
AC4C	A360 (US), AlSi9Cu3 (EU)	240-310	170-220	90-120	3-5	95-120	2.65-2.75	Automotive, high-performance die casting
AC7A	A380 (US), AlSi8Cu3 (EU)	230-300	150-200	80-100	2-4	90-115	2.65-2.75	Automotive, industrial, general-purpose die casting
AC8A	A413 (US)	210-280	140-190	75-90	3-5	85-110	2.60-2.75	Automotive, thin-walled parts, precision die casting
AlSi12	AlSi12 (EU)	200-270	150-220	80-100	2-4	85-110	2.60-2.70	Automotive, high-performance, wear-resistant parts
AlZn10Si8Mg	A356 (US)	350-400	270-350	180-220	5-7	150-170	2.60-2.70	Engine components, structural and high-strength parts

Typical Surface Treatment for Aluminum Die Castings

Typical surface treatments for aluminum die castings include anodizing, arc anodizing, chromate conversion coating, powder coating, electroplating, painting, polishing, shot blasting, vibratory finishing, chemical etching, clear coating, and heat treatment. These processes enhance properties such as corrosion resistance, wear resistance, appearance, and strength, while also improving durability and performance in various industrial applications.

Surface Treatment	Description	Purpose/Benefit	Applications
Anodizing	Electrochemical process that forms a durable oxide layer on the surface of the aluminum.	Increases corrosion resistance and wear resistance; enhances appearance.	Automotive parts, cookware, aerospace, electronics, architectural finishes.
Arc Anodizing	A type of anodizing that uses electrical arcs to produce a thicker and harder oxide coating on aluminum.	Provides superior wear resistance, durability, and aesthetic appeal, especially for harsh environments.	Aerospace, military, high-end automotive, industrial machinery, marine environments.
Chromate Conversion Coating	A chemical treatment that creates a protective layer on the aluminum surface.	Provides corrosion resistance and improves paint adhesion.	Aerospace, automotive, military, electrical connectors, industrial equipment.
Powder Coating	A dry finishing process where a powdered coating is applied and then cured under heat.	Enhances corrosion resistance, improves aesthetics, and offers durable finishes.	Automotive parts, household appliances, furniture, architectural components, outdoor equipment.
Electroplating (Nickel, Zinc, etc.)	The process of depositing a metal layer onto the aluminum surface through electrochemical means.	Improves corrosion resistance and surface hardness, and enhances appearance.	Automotive, electrical components, hardware, household products, decorative items.
Painting	Application of liquid paints for decorative and protective purposes.	Offers color, increased durability, and corrosion resistance.	Consumer products, automotive, machinery, outdoor products, furniture.
Polishing	Mechanical or chemical polishing to create a smooth, shiny surface.	Improves surface finish and aesthetic appeal, often used for decorative purposes.	Jewelry, automotive, consumer electronics, decorative architectural elements.
Shot Blasting	High-pressure blasting of abrasive particles onto the surface to clean or texture it.	Improves surface texture, removes casting defects, and enhances paint adhesion.	Metalworking, automotive, aerospace, construction, foundries.
Vibratory Finishing	Using abrasive media in a vibrating machine to smooth surfaces.	Reduces surface roughness and deburrs parts.	Automotive, aerospace, medical device manufacturing, jewelry finishing.
Chemical Etching	Use of chemicals to etch away unwanted material from the surface.	Provides fine surface finishes, often used for engraving or creating textured finishes.	Electronics, signage, jewelry, precision machining, aerospace.
Clear Coating	Application of a transparent coating to preserve the natural finish of aluminum.	Provides UV and corrosion resistance while maintaining the metallic look.	Automotive, electronics, marine, architectural, jewelry.
Heat Treatment	Controlled heating and cooling process to alter the mechanical properties of aluminum.	Enhances strength and hardness of the cast aluminum part.	Aerospace, automotive, machinery, defense, high-performance parts.

Applications of Aluminum Die Castings

Aluminum die casting delivers lightweight, high-strength solutions across industries. From durable automotive engine components to aerospace structures, consumer electronics housings, and industrial machinery parts, its precision and reliability stand out. Ideal for medical devices, marine applications, thermal management, and LED lighting, aluminum die casting ensures efficiency, durability, and corrosion resistance.

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Aluminum Die Castings Design

Good design in aluminum die castings offers several advantages, including improved strength, reduced material waste, and faster production times. It ensures uniform wall thickness, optimal metal flow, and minimizes defects like porosity. Additionally, it enhances part durability, reduces post-processing needs, and allows for precise tolerances, ultimately lowering costs and increasing the overall quality and efficiency of manufacturing.

Design Elements	Specific Value/Range
Uniform Wall Thickness	Aim for wall thickness between 2.5mm to 4mm for optimal casting flow and strength. Thicker walls can lead to defects.

Draft Angles	Use a 2° to 3° draft angle on vertical surfaces to ease part removal and avoid damage to the mold or part.

Radii and Fillets	Implement a 3mm to 5mm radius at corners and edges to reduce stress concentrations and improve flow.

Avoid Sharp Corners	Corners should have at least a 3mm radius to avoid stress and ensure better mold filling.

Incorporate Ribs and Bosses	Use ribs at 0.5mm to 1.5mm thickness, spaced 2 to 3 times their thickness apart for optimal strength and material efficiency.

Correct Gate Placement	Place gates at the thickest part of the casting, and aim for a gate thickness of 2mm to 3mm to avoid cold shuts and ensure even metal flow.

Optimized Thickness for Strength	For strength and lightweight designs, maintain a balance of 2.5mm to 4mm wall thickness, reducing material wastage while ensuring durability.

Proper Tooling Design	Ensure vents are placed every 30-50mm on the part, and runners should be 6-8mm wide for proper metal flow and air evacuation.

Consider Post-Processing Needs	Account for 0.2mm to 0.5mm tolerance for any CNC machining or surface finishing processes.

Avoid Deep Blind Holes	If possible, avoid blind holes deeper than 2x their diameter; if required, ensure they are easily accessible or consider through holes.

Minimize Undercuts	Aim to keep undercuts to a minimum and use a core pull or side-action tooling for more complex geometries, or simplify the design.