There are several advantages to aluminum die casting for a new part. Aluminum die castings are lightweight, corrosion-resistant, have high thermal and electrical conductivity, and are durable. They remain strong at high temperatures and retain their dimensional stability even if the part has thin walls or is a complex shape.
Aluminum die castings also have excellent mechanical properties, making them a popular alternative to steel and iron. This is especially true for the automotive industry, which is continually seeking lightweight, durable materials.
Benefits of Aluminum Die Casting
Aluminum can be cast in various ways. The benefit of using the high-pressure die casting process over other aluminum casting processes is lower part cost. The aluminum high-pressure die casting process can produce a near-net shape in seconds.
Though high-pressure die casting tooling is more expensive than other casting processes, the heat-treated steel and water-cooled die cast die might produce 75K-200K “shots” over its life. Depending upon the part size, geometry, and demand, tools can often be built to produce multiple parts in one “shot,” This further reduces the part price and allows the tooling cost to be amortized over large quantities of parts.
Aluminum is the most popular die casting material because it is economical and provides a good mix of properties. Due to its valuable properties, numerous parts from numerous industries—like automotive, medical, and alternative energy—are cast via aluminum die casting.
Aluminum Die Casting and Die Life Considerations
Certain considerations must be considered before building the die to maximize die life. Factors that contribute to die life include:
- The overall design of the part
- Type of tool used to create the die
- Configuration of the mold
- Die steel, heat-treating techniques, and die coatings
- Expectations for part quality
Before a die is built, the customer presents a concept or existing part to a die caster. A die cast engineer will assess the project from design to end product and work with the customer to optimize the part design for die casting. An initial discussion with the die caster may include topics such as:
- Functional and cosmetic requirements
- Tolerances
- Annual and lifetime volume
- Alloy choice
- Mating parts
- Project timing
- Optimizing wall thickness
Importance of Partnering with an Experienced Die Caster
An experienced die caster will consult with you about your application and assist you with product design. They will then design the tooling to produce parts with repeatable dimensions, excellent surface quality, consistent mechanical properties, and long tool life.
These factors provide the greatest opportunity for cost savings and maximizing value. A less experienced die caster might offer lower initial costs, but this could cost you in the long run due to quality, delivery, or tool life issues. A die built to lower specifications will likely fail at an inopportune moment, shutting down production and forcing you to spend much more than you initially thought you saved.
Contact Chicago White Metal Today
Chicago White Metal Casting (CWM) has 83 years of experience providing our customers with excellent service, saving you money, and resulting in products you and your customers will love. Contact us online to learn more about our aluminum die casting service or other capabilities. You can also reach us at +1 630-595-4425 or via email (sales@cwmtl.com) if you have any questions. You can also click here to request a quote online.
