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Aluminum Die Casting

A380 is the workhorse alloy for aluminum die casting.

A380 is the most popular metal choice for aluminum die casting. Because it offers the best combination of mechanical and physical properties, A380 provides several advantages:

  • Lightweight
  • Retain high dimensional stability with thin walls and complex shapes
  • Corrosion resistant
  • Good mechanical properties
  • High thermal and electrical conductivity
  • High strength—even at high temperatures

For more information on the physical and mechanical properties of Die Cast Aluminum Alloy A380, download the NADCA datasheet HERE.

With 10 aluminum casting machines, ranging from 300 to 800 tons of locking force, CWM can produce parts in a range of sizes from 0.75′ x 0.75″ to 18” x 18″.

Aluminum die casting is used frequently in the automotive industry, as a durable, lightweight alternative to steel and iron.  Its electrical and thermal conductivity properties make it well suited for the telecommunications and computer industries.  And, its dimensional stability and mechanical properties make aluminum the metal of choice for a wide variety of industries and their parts.    

Request a quote or contact Chicago White Metal for more information.

Aluminum Die Cast Components from CWM
Aluminum die cast baseplate part for dental workstation
Aluminum die cast baseplate part for dental workstation. The 6 in. x 8.5 in. aluminum die casting design earned a NADCA award due to an optimum gating and runner system that allowed consistent metal flow.

Learn More About Aluminium Die Casting:

The Market for Aluminum Alloys in North America: Trends and Challenges

Martin Hartlieb, President of Viami International Inc., describes the industry for aluminum alloys market in North America. This article studies trends and challenges from both various international resource centers. (OEM Tech Brief, No. 50)

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10 Ways to Reduce the Costs of Die Cast Parts

6-page guide outlines 10 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. These specific planning steps aid in integrating the realities of die cast manufacturing.

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1st-ever Triple Winners in NADCA Die Casting Contest

Two Al and one Mg die casting Awards were won by CWM for a first-ever triple win for outstanding custom die castings in the annual North American Die Casting Association’s International Die Casting Competition.(Includes photos)

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Al Archery Bow NADCA Die Casting Award Winner

The central component for a newly developed archery bow for serious young archers is a high-tech Al die casting produced to precision tolerance specifications and machined look and feel of a “hog out.” Delivered at the targeted market price, on tightened time schedule to tie-in with promotional book and film release dates. NADCA Die Casting Award of Excellence winner. (Includes photos)

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CWM Al, Mg & Zn Die Cast Production Specs 

2-page descriptive detailed data sheet for Chicago White Metal Casting’s current high-tech production specifications, material properties and nominal chemistry for its Al, Mg & Zn alloy capabilities.

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CWM Comprehensive Die Casting Capabilities Brochure

16-page, full-color comprehensive brochure on Chicago White Metal Casting capabilities in the most widely specified die casting alloys— Al, Mg & Zn. From design assistance through production, post-casting machining, surface finishing and final product assembly. Detailed overview covers the experience, advanced technologies, and ISO 9001 & 14001 registered management systems that make CWM the cost-effective choice for net- and near-net-shape die cast parts. Includes case examples.

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Design & Specification Guide for Custom Die Castings

Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines.

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Die Casting Design & Production Preplanning Guide

Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents.

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Dirt Bike Al Hub with 35 Gear Teeth Cast to Zero Draft

First motocross design produced on American soil in 20 years features many rule-breaking design innovations, such as its “sweet,” solid shifting clutch, made with two high-tech Al die castings. The Al hub has 35 gear teeth cast to zero draft. The crankshaft and engine cover are AZ91D hot-chamber mag die castings, providing strength and lightweight.

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High-Tech Al & Mg for Advanced Video Imaging System

Designed as part of an advanced digital video processing and control system, Sony engineers specified “perfect parts” for their new professional video camera. CWM high-tech die casting was selected to produce 11 aluminum and hot-chamber magnesium housing components for the new camera. Superior as-cast surfaces were primary specifications.

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Intricate Al Die Cast Propane Vaporizer-Regulator

Two intricate Al die castings are the heart of a vaporizer-regulator for propane and natural gas vehicles, winning an industry award for their casting excellence. Meeting important thermal and weight specs, the two castings that make up the unit have channel walls, and the spaces between them, that measure 0.040 in. (1.016 mm) thick.

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Material / Physical Properties Comparison

This chart compares the material and physical properties for three popular die casting alloys: aluminum A380, magnesium AZ91D, Zinc #3 and ZA8. Several material properties such as tensile strength, impact and yield strength can be compared between the three alloys. Physical properties such as density and conductivity can also be examined.

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NADCA Standards: Aluminum Alloy Data

Al alloy selection, machining and finishing data; chemical composition; material properties and die casting and other characteristics.

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Product Solutions Through Die Casting

Presentation to aid efficiency, functionality and cost savings in the design and production of custom die castings. This narrated webinar focuses on helping effectively capitalize on today’s advanced die casting capabilities to improve performance and lower the costs of their custom components. 1 hour.

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Prototyping for Die Casting in All Alloys

Guide to developing optimum prototyping strategies for developing and testing component designs prior to final die casting die construction. Discusses prototyping alloys and processes, including new rapid prototyping technologies.

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Quick Guide to Surface Finishing for Al, Mg & Zn Parts

8-page condensed resource on evaluating finishing alternatives and optimizing component finishing decisions for Al, Mg and Zn die cast products. Features a comparison table rating 32 surface coatings on relative cost, appearance, wear and corrosion resistance; Presents recommended finishing for a range of typical die cast components.

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Rugged Al Die Cast Laser Housing Outperforms Plastic

A wireless remote laser unit to aid pipelaying accuracy and efficiency is claimed to be the most powerful laser device of its kind allowed by law. New model offers an Al die cast metal housing to meet extreme, rugged field conditions, difficult for plastic housings to survive.

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Surface Finishes for Die Casting

Presents the important factors that can affect the outcome of the final appearance of your die cast component when its surface finish is a critical issue. This narrated webinar will aid an understanding of the various finish options, and how their uses and limitations can make the difference between successful product development and costly results. 49 minutes.

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NADCA-ADCI Standards Cross-Reference Chart

Cross-reference chart for former superseded American Die Casting Institute (ADCI) and superseded North American Die Casting Assn. #401 (NADCA) Product Standards and current NADCA Product Standards. (2015)

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The Die Casting Process: An OEM Designer’s Overview

This overview for OEM designers and specifiers is a refresher for those OEM product design engineers, buyers and purchasing managers already familiar with die casting; and for those new to the process it provides a valuable framework or further pursuit.

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The U.S. Aluminum Casting Industry

This white paper is a 6-page excerpt of an article that describes the current state of the United States Aluminum Casting Industry as it relates to Aluminum Die Casting. This article was written by The Folk Group. (Truncated Version)

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