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.

Precision Casting Provides You the Easiest Way to Maintain Accuracy and Quality

The use of metals in today’s world is much more than one can expect. Almost each and every industry requires metals in some form or the other. Manufacturing industries use metals as raw materials in the production of different types of goods. Simple instruments, kitchen equipment, machinery, electronic goods and items, scientific instruments and equipment, furniture, decorative items, and all such types of goods use metals as major raw materials. Manufacture of metals uses different processes based on the requirement. Precision casting is the one of the most commonly used process for the manufacture of metals. Several industries use this form because of the advantages it has got over all the other processes.

A precision die cast metal is considered to be superior over all others. This is because of all the advantages it has got:

• Weight
The products made using this process are much lighter in weight than the metal parts made with all other kinds of processes.

• Simpler Assembly
Coring holes and tapping them to drill sizes are made possible. It is possible to cast internal and external threads.

• Multiple Finishing Techniques
The surfaces of the casts can be made smooth and textured. It is also possible to plate them easily and create multiple finishes. Very little surface preparation is required to make this possible.

• Strength
The products made using precision casting are much stronger than those of same dimensions made with all other processes, including the plastic injection techniques. The walls are thinner, and they are much stronger.

• Stability
As far as die cast products are concerned, stability is a very important factor. These products are dimensionally stable and highly durable. They are also resistant to heat.

• Accuracy
All the elements using the process maintain close tolerances. They are highly accurate.

• Production Rate
It is possible to make complex shapes that have high tolerances. The tolerance achieved using this process is much higher than that achieved with any other mass production process. Very little or no machining is required for this process. A large number of identical castings can be produced easily.

A precision die cast process can produce parts with different alloys and elements. Zinc, aluminum and magnesium are the most commonly used. Good quality metal parts with high accuracy can be produced easily, and that is why it is commonly used by most manufacturing industries. You could also use the process to make metals parts of the best quality for all your purposes.

Metal Parts Manufacturing – An Overview

Metal parts are commonly used for manufacturing different kinds of equipment, machinery, and other tools and items required in day to day lives. All kinds of items that we use have some part or the other that uses metal. Different kinds of metals like zinc, iron, copper, and so on are used for these purposes. Manufacturing these metal items require a lot of precision and care. They need to be of the exact dimensions and specifications required, or else they will never be able to serve the intended purpose. So, there are a number of strict guidelines that need to be followed.

In the manufacturing process, a number of raw materials are required:

·         Plate metal

·         Formed and expanded metal

·         Welding rod or wire

·         Castings

·         Hardware

·         Fittings

Manufacturing metal parts involves different processes:

·         Cutting

This is the initial step that is composed of sawing, shearing, and chiseling. They can be either manual or automated. Torches, numerical control cutters, and other such tools are used here.

·         Bending

Hammering is employed to bend the metal piece. Press brakes and other such tools may also be used for this purpose. This also can be manual or automated.

·         Assembling

Assembling involves a number of steps like welding, binding with adhesives, threaded fasteners, and riveting. As a starting material, sheet metal and structural steel are also used along with the flux, wire, and such fasteners to join all the cut pieces together. Here also, you can use either human labor or automated processes to get the job done.

To get your metal equipments ready, you can contact metal manufacturers to get the spare parts. There are several manufacturing companies that specialize in their own style of manufacturing. There are different kinds of processes employed in manufacturing the spare parts. Each kind has got its own advantages and disadvantages. Different companies have their own style and processes as well. There is no hard cut rule for manufacturing.

Before you choose one among all the metal manufacturers available, you need to do a bit of a research to get the best. You can consult friends and relatives who have experience in this field, or any such people who can help you choose the best. Knowing the trends in the market is also very important. Approach a company that is known for its accurate and precise work along with timely delivery and efficient service. Only getting the best in class parts will be able to properly perform the function needed. They need to conform to all standards and also last long enough. Moreover, the rates must also be affordable and according to the current market rates.