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How Does Aluminum Die Casting Work?



The production of Aluminum passes through different phases. The process of designing an aluminum part has a different manufacturing process. The most common method that industries can use to produce Aluminum is Aluminum die casting. It is the method adopted by most of the automotive sector, telecommunication industry, and aerospace industry. Electric, hydraulic cylinders, and Led lightings are made using this method. The manufacturing industry can use this process to produce different products.

The Aluminum die casting process.

The Aluminum ingots of the alloy are heated to a high temperature to melt them so they can be cast. This molten Aluminum can now be molded into any shape. The injector is used to deliver the molten metal. Then molten metal is injected with high pressure into the mold cavity. The metal mold consists of two parts that can be separated easily. The parts are taken apart when the metal cools down and an aluminum cast appears.

The aluminum product now formed has smooth surfaces. If needed, it can be smoothed down further using sandpaper. As still die are used, they can be reused to make aluminum cast products. This method is used to produce high-volume aluminum die casting parts on an industrial scale. This metal forming die process can be used to create complex design aluminum parts. They have high tensile strength and more level of accuracy.

The benefit of the Aluminum Die Casting Process

Aluminum casting has its advantages over other metal forming processes. It can be the best choice for aluminum parts manufacturers. The most crucial feature of die casting is that it can create the most complex design. Other methods such as extrusion or machining can never effectively create smooth, complex forms. It can also be used to make medical equipment. It has a high shear strength.


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Automotive industries

Automotive vehicle engine parts and transmission blocks are the best examples of complex parts. They are produced with high precision using the die casting method. Moreover, smooth and textured parts can also be created using this method. They can withstand high operating temperatures.

One key feature of die casting is that it can produce small and large parts with the most precision. It can achieve the complexity and tolerance of aluminum automotive parts. There are many reasons that Aluminum is used worldwide. It is a nonferrous metal that is lightweight. This feature makes it the most used metal in the production of automobile parts. The die casting process can produce strong and lightweight products.

Aluminum Die Casted Products

The Aluminum die casting parts have a nice surface finish. They can work at high temperatures as compared to other nonferrous materials. These parts are highly conductive, corrosion-resistant, and have good stiffness. They also have a strong strength-to-weight ratio.


This process relies on rapid production that can produce many products using die casting as they are made quickly, so less energy is used, making this process more cost-effective than other metal forming processes. Die casting has become the most used process for the production of parts.

Characteristics and Advantages of Aluminum Die Castings include:

  • Good strength-to-weight Ratio
  • Great Resistance to Corrosion
  • Lightweight and Durable
  • Fully Recyclable and Reusable in Production
  • Excellent Electrical Conductivity

Considerations During Die-Cast Alloy Design

When a die-cast is designed, some key points must be considered. The mold should always be designed in 2 parts that can be separated easily. When the molten metal cools, it can be taken out easily. One should consider where to put the parting line when designing the die. This line tells us where the die will open when the Aluminum needs to be removed. The parting line should be considered in the early stages of die design.

Another important factor is considering where the injector will go inside the die. The location should be considered wisely so that the molten metal reaches every cavity inside the die. For this, several injectors should be considered.

One should also consider the minimum wall thickness for parts. These days the thickness is not considered much. But constant thickness should be preferred in walls.

Green Sand Casting and Permanent Mold Casting

Two other methods are used in the industry to make parts. Green sand casting and permanent mold are the two alternatives that are used widely. The green sand process is much cheaper as it uses sand to create a mold for the casting. After the mold is made, the molten metal is poured into the sand-cast mold. In sand molding, pressure is not needed. The metal pours into the mold by gravity.


In permanent mold casting, the molten metal is poured into the mold. It produces a strong cast and good quality products. However, the Aluminum die casting offers a better-finished product with more tolerance. This method does not require surface treatment in most cases.

Machining and Finishing

In Aluminum casting, parts mostly never require any machining if needed; several options are available. The surface finishing is most perfect in die casting. It has a good surface finish compared to other metal forming processes, but still, some imperfections can occur. They mostly occur at ends where the mold opens and halves meet. These imperfections can be removed using sanding, orbital sanding, and sandblasting methods. The Aluminum die-casted parts have more finish.

The protective powder coating is applied to the finished product. A powder coat is applied that makes it last longer. Modifications, such as drill trapping, can be applied to the cast after its form.

Common Alloy of Aluminum Die Casting

The most used Aluminum die casting are A380, 383, B390, A413, A360, and CC401. These die are selected based on the desired product that you want. A360 die offers excellent pressure tightness and corrosion resistance. B390 has a low ductility of cast alloy but at the same time offers to wear resistance that has high hardness.


The Alloy A380 is called the jack of all trades. It has the best combination of all the alloys. It is the most widely used alloy for the casting of Aluminum.


In most cases, the metal forming process depends on the budget. The die casting method is perfect for you if you want to produce many parts for automobiles.


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