Aluminum Die Casting | Types of Die Casting

Aluminum Die Casting is a manufacturing process of melting aluminum alloy and injecting it into a mold cavity under high pressure. The molten metal solidifies quickly, forming a solid cast component that conforms to the shape of the die mold or cavity. The Aluminum Die Cast process is commonly used to produce very complex and intricate parts with good surface finish and high precision.

Types of Die Casting

The various types of  Aluminum Die Cast processes or techniques used in the manufacturing industries are:

• High-Pressure Die Casting (Hot Chamber and Cold Chamber Die Casting)
• Gravity Die Casting (Also known as Permanent Mold Casting)
• Low-Pressure Die Casting

High Pressure Die Casting Process

• High-pressure die Casting is the process of producing metal components by forcing molten metal with high pressure and velocity into the die cavity. 
• HPDC is a versatile process and the most rapid way of producing non-ferrous type metal parts such as Aluminum, Zinc, Copper, etc.
• By using HPDC processes, small parts, thin wall sections, intricate details, and high surface finish can be achieved.
• The tooling and machinery/equipment cost is very high.
• The HPDC process is suitable for high production volume.
• The pressure of the molten metal entering into the die cavity is higher than the atmospheric pressure which makes the die casting process different from the gravity die casting and other pouring processes such as sand casting and permanent mold casting process.

Low Pressure Die Casting Process

• In the LPDC process, molten metal is injected into the die cavity by low pressure.
• There is very small metal turbulence as the molten metal flows in smoothly.
• The LPDC process is most suitable for rotationally symmetrical parts.
• Aluminum Alloy Wheels, as well as suspension, steering, and engine components, are good examples of LPDC.

Gravity Die Casting Process

• Gravity Die Casting is the process where the molten metal is poured into the mold by ladle or vessel. The only force acting on the mold cavity is gravity, and filling is regulated by tilting the die.
• The GDC process is also known as the permanent mold die-casting process.
• The tooling and machinery/equipment cost is low.
• The GDC process is suitable for Low production volume.

Advantages | Die Casting Aluminum

1. Rapid production:  Die Casting Aluminum allows for high-volume production with fast cycle times. The quick solidification of the aluminum allows for multiple parts to be produced in a short amount of time.

2. Cost-effective: Aluminum is a relatively low-cost material, making die casting a cost-effective manufacturing method. The tooling costs for the molds can be high initially, but the efficiency of the process offsets these costs over time.

3. Lightweight and strong: Aluminum is lightweight yet strong, making it suitable for a wide range of applications. Die-cast aluminum parts have excellent strength-to-weight ratios, allowing for durable and efficient components.

4. Complex shapes and designs: The die-casting process enables the production of complex and intricate shapes that may be difficult to achieve with other manufacturing methods. It allows for the inclusion of features such as ribs, bosses, and thin walls in the final product.

5. Good surface finish: Die casting produces parts with a smooth surface finish, reducing the need for additional finishing operations. This helps in achieving a high-quality aesthetic appearance for the components.

Aluminum Die Cast Applications 

Aluminum die casting process is commonly used in various industries, including automotive, aerospace, electronics, and consumer goods. It offers a flexible and effective method for creating high-quality aluminum components with precise tolerances and superior mechanical qualities.