Aluminum die casting process | Aluminum die casting alloys

Aluminum Die Casting Process

Aluminum die casting process is defined as the injection of molten metal into the die cavity and allows it to solidify to form a casting with the desired shape and size.

When the injection of aluminum molten metal into a die cavity is done by applying high pressure using a piston-cylinder arrangement, it is called a High Pressure Aluminum Die Casting Process-HPDC.

When the injection of aluminum molten metal into the die cavity is done by gravitational force by tilting the die, then it is called a Gravity Die Casting Process-GDC.

The manufacturing process flow of Aluminum Die Casting Process are as follow:

• Receipt of Raw Material-Aluminum Ingots.
• Storage of RM with proper color coding and heat number identification.
• Aluminum Alloy Melting.
• Metal treatment or purification by flux addition and Degassing process.
• Molten metal pouring and casting.
• Fettling/Gate cutting/Grinding
• Heat treatment to remove internal stresses and achieve desired hardness in casting (if applicable).
• Buffing/Shot blasting (if applicable).
• Machining process (if applicable).
• Final Quality Inspection
• Packing and Dispatch

Aluminum Die Casting Alloys

Various aluminum grades are used in casting industries based on part applications, required strength, and customer requirements. Some of the die-casting aluminum alloys are listed below:

 ADC12, ADC6, A380, A413, B390

ADC12 is used for highly intricate components. ADC12 is also known as A383 and is often used as an alternative to A380 alloy. Better corrosion resistance, lightweight, ease of casting, strong mechanical qualities, and dimensional stability are some of its advantages.

Aluminum alloy A380 – The best casting, mechanical, and thermal characteristics are provided by it.
It has exceptional fluidity, pressure tightness, and hot crack resistance.
It is utilized for a wide range of items, including engine brackets, gearbox cases, home furnishings, power tools, and hand tools.

Aluminum alloy A413- It has exceptional pressure tightness. It is a suitable option for hydraulic cylinders because of this. This aluminum alloy is a fantastic option for die-casting complex components because of its castability.

Aluminium alloy B390- It has a high degree of hardness and exceptional wear resistance. This alloy is appropriate for a variety of uses, including cylinder bodies for compressors and brakes as well as pistons for internal combustion engines.

Aluminum Casting Alloys Characteristics

• Very good strength 
• Good Hardness and Stiffness
• High operating temperatures
• Highly corrosion resistance
• Lightweight and full Recyclability
• High thermal and electrical conductivity
• Good finishing characteristics

High-Pressure Die Casting Process Parameters

Process parameters	Unit of Measurement
High-pressure pump	kg / cm2
Low-pressure Pump	kg / cm2
Accumulator pressure	kg / cm2
Ejection pressure	kg / cm2
Nitrogen pressure	kg / cm2
Ejection   pressure hold time	Second
Die Open time	Second
Low speed of the plunger	Turn – mk/s
High speed of the plunger	Turn – mk/s
Intensify speed	Turn – mk/s
High-speed Position	mm
Length of the biscuit	mm
Temperature- Fixed die	( OC)
Temperature -Moving Die	( OC)
Temperature of Metal	( OC)
Temperature of oil	( OC)
Spray  pipe condition	OK /NOT OK
Die Lubrication Time	Second
High Cooling Fixed  side	Working/ Not  Working
Die  Cooling Moving side	Working/ Not  Working
Level of the Oil	Above the below  Level
Lubrication oil level	Above the below  Level
Lubrication  pump	Working/ Not  Working
Oil/Water Leakage	No Leakage
Condition of the thermocouple	OK/NOT OK
Any abnormal noise in the machine	No any abnormal noise
Die Clamp	Tighten / Loose
Water leakage from the Die and machine	No leakage
Machine auto ladle	Working / Not working
Machine auto extractor	Working / Not working
Machine auto spray	Working /Not working