Aluminium Die Casting – Efficient, Durable and Versatile

Metal die casting is a process that is being used in a number of industries for efficient and effective product manufacturing. This process involves melting a metal and forcing it to pass through cavities or chambers at high pressure and then allowed to cool. After the metal cools, it takes up the shape of the die cast. This method reduces time and effort required in manufacturing a number of products. Though a number of non-ferrous materials are used in die casting, aluminium is generally preferred in a range of applications.

There are many benefits of using aluminium die castings. First, this metal is lightweight and is highly corrosion resistant, which makes it suitable for use in a variety of applications. Moreover aluminium is strong, stiff, hard and has a high strength to wait ratio. All the features make it highly suitable for use in automobile part manufacturing. Its high thermal and electrical conductivity make aluminium a great choice for telecom and computing industries. These attributes also make this metal perfect for use in electrical housings and connectors. Above all, aluminium has good EMI and RFI shielding properties, so it is suitable for use in the manufacture of handheld devices. Plus, aluminium retains its strength even at very high temperatures. So, even if it is melted and then cooled, it will not lose its original attributes. All these features make this metal perfect for die casting.

There are basically two methods used for die casting - hot chamber or cold chamber. While die casting aluminium, the cold chamber method is preferred over the hot chamber method as aluminium may react with iron when it is heated to a very high temperature. In the high pressure aluminium die casting, a separate chamber is used to melt the metal. When the metal alloy reaches the molten stage, the required amount is slowly transferred into the cold chamber, and into the hydraulic piston. Using this technique, high number of casts with high-quality casts can be produced over time. Different types of aluminium alloys are used in various manufacturing processes. The most commonly used alloys are A380, 413 and 383.

High pressure aluminium die casting is a versatile technique that is not only efficient, but also allows manufacturers to design and create high-quality durable die casts. 

Aluminium Alloy Vs Magnesium Alloy Die Casting

Die casting is a process in which molten metal is forced into a chamber at very high pressure. When the metal cools, it forms the shape of the mould. In order to prevent any type of reaction, the cast is made of non-ferrous metals such as steel, copper, aluminium, zinc, magnesium and their alloys. This metal casting process is relatively simple and doesn’t need a large investment. 

Both magnesium and aluminium alloy are used for die casting process. Both have their own advantages and disadvantages.


Melting Point

The melting point of the metal is the first point of comparison between the two alloys. Magnesium has a melting point of 1800 LB while aluminium has 2500 LB. As aluminium alloy has a lower melting point than magnesium alloy, it will make an economical choice. Again the choice of alloy depends on the type of furnace and melting pot.


Melt Loss

Another point of difference between the two alloys is the melt loss, which depends on the type of die casting technique used. Generally during magnesium casting, melt loss of 5 to 25% is seen while aluminium has less melt loss of 5 to 10%.


Cost

Another point that is generally taken into consideration while choosing either of the two alloys is the cost of production. Magnesium has a quick solidification rate, so, it doesn’t need high pressure like aluminium to be solidified. In many ways, it can be seen that magnesium alloy is more economical than aluminium die casting.


Machinability

While comparing the machines used to die cast both alloys, it is seen that magnesium is advantageous over aluminium. Magnesium machines have natural lubricity and quickly dissipate heat, which enables carving deep cuts without damaging the surface finish. Plus, more magnesium castings can be made as the die caster has a high tolerance to this metal than to aluminium alloy. When you compare the lifespan of carbide tools used to machine magnesium and aluminium, you will see that they last up to 10 times longer when used with magnesium.


Applications


Generally aluminium is used in die casting of automotive parts such as clutch pedal and support bracket. If the die caster is using a hot chamber die casting machine, then magnesium die casting requires 160 metric ton. For, aluminium die casting, it will require a 550-650 metric ton cold chamber die casting machine to do the same. Here, if you compare the price with the machine size required, then magnesium alloy becomes a more affordable option.