Aluminum Die Casting
Aluminum alloys possess high dimensional stability even when cast into complex shapes with thin walls. Aluminum die casting is efficient and economical and offers a wide range of durable shapes and components. Little or no machining is required after an aluminum part is die cast, because the process provides very close tolerances even during the production of very complex shapes.
Aluminum die castings can also be easily plated or finished. Aluminum’s dimensional stability and heat resistance make it an ideal material for cast valve covers in automotive applications. Aluminum die castings are also commonly used in the production of hardware and tools because of their excellent resistance to corrosion and high temperatures. Because of the versatility of aluminum die castings, they can be found in aerospace applications, on boats, in plumbing systems and in an extensive variety of other applications.
Aluminum die casting is a metal forming process in which molten aluminum metal is put under pressure and injected into a die. Aluminum die casts are lightweight alloys that feature good corrosion resistance, very favorable mechanical properties, high thermal and electrical conductivity and strength at high temperatures.
Metal castings have become an essential part of industry and commerce. Since the creation of the earliest recorded metal casting over four millennia ago, castings have come to occupy a very important part in innumerable industrial processes as well as in commercial and consumer products contexts. Despite the advances in casting technology since its inception, the basic concept of metal casting remains unchanged. In the specific context of aluminum casting, the process begins with a collection of raw material in a reservoir. That aluminum is then heated and pressurized until it becomes molten. Once molten, the aluminum is forced into a mold cavity that is specially designed to give the aluminum a new shape.
Once all of the aluminum has been forced into the mold, it forms around the contours of the mold. After having taken the mold’s shape, the aluminum is allowed to cool, which causes it to become hard again. Once completely hardened and cooled, the metal is ejected from the mold as a newly die cast aluminum product. The product can then be prepared for shipment to customers, or, in rare cases, sent for additional processing. Because of aluminum’s high melting point, aluminum casting must be performed in a cold chamber die caster. Aluminum die casting can be more energy intensive than other metal die casting processes, but many manufacturers still employ it because of the many benefits it presents.