Introduction
Die casting has been in existence since the mid-century. It was first invented to produce a movable type needed by the printing industry. However, today, it has expanded to other sectors which include; automotive, electronics, aerospace and marine. It majorly uses non-ferrous metals which are magnesium, zinc and aluminum. This article will expound on the use of aluminum. If you are curious as to how this works, then, read on.
What is aluminum die casting?
Aluminum die casting is a manufacturing process that allows for the creation of complex aluminum shapes by using molten aluminum, which is injected into a steel mold (or die) under high pressure. The aluminium casting process begins with heating aluminum ingots until they are fully melted into a liquid state. This molten aluminum is then poured or forced into a precisely designed mold cavity under high pressure, ensuring that it fills all intricate details of the mold.
The high-pressure environment helps achieve a smooth surface finish and dimensional accuracy in the final product. After the aluminum cools and solidifies within the mold, the cast aluminium is ejected from the die. The die can be reused multiple times for casting additional parts. There are two main types of die casting processes: low-pressure and high-pressure die casting. High-pressure die casting is particularly suited for producing complex aluminum parts that require detailed accuracy and strength. This method is widely used in industries such as automotive, aerospace, and electronics for mass production of high-quality aluminum components.
Benefits of using aluminum for die casting
Aluminum is a metal used for different purposes. What makes it more preferable in manufacturing industries include it’s strength, ability to resist corrosion and durability. It is ready-made for machine preparation. Aluminum die casting process produces parts with more surface finishing options. It can endure operating under high temperatures of the die cast alloys. Aluminum is also versatile and has corrosion resistance. It maintains its original dimension when with thin walls. It has lower density which allows for weight reduction where it is necessary. Aluminum alloys for casting allows for high strength while maintaining a low weight which makes it possible for structural applications. It also works as a cover which protects electronic products from electromagnetic interference and radio-frequency interference.
An aluminum alloy for casting has a high thermal conductivity range of 100-240 W/m.K which means it absorbs heat at a fast rate, shares it uniformly and disperses heat quickly. This conductivity is higher than stainless steel (15-30W/m.K) and lower than copper (386 W/m.K). Additionally, it can be fully recycled without losing its properties, making it ideal for the die casting process. This shows that it has some level of flexibility. Lastly, it is cheaper than other processes of machining metals
Other non-ferrous metals such as zinc, magnesium and copper are other materials used in die casting. The comparison of zinc die cast vs aluminum, magnesium vs aluminum die cast and aluminum vs copper die cast shows that there is variety in conductivity, melting point, resistance to corrosion and weight.
Best aluminum alloys for die casting
Do you want to know more about the properties, advantages, applications of the best aluminum for casting? Read on to gain more insight.
A360
A360 die casting material is an aluminum alloy casting material that design engineers use as an alternative to A380. The main alloying element of A360 is silicon (9.0-10.0%) which is mostly used for die castings. This aluminum alloy allows for lighter weight, strength-to-weight ratio, high resistance to corrosion and excellent formation performance. It has pressure tightness and good fluidity. The A360 aluminum material is suitable for many applications. This alloy’s resistance to corrosion makes it suitable for the production of outboard motors and other marine appliances. It is also good for the invention of automotive parts like luggage mounts. This aluminum die casting alloy is also used by manufacturers to make hydraulic cylinders and irrigation system parts.
A380
This aluminum casting material is one of the most common die casting material because it has a combination of some aluminum die casting components which exhibit; easy castability, easy machinability, fair resistance to corrosion, very good resistance to hot cracking, good anodizing, good machinability, high strength, high flexibility and good transfer of heat. Even though this aluminum alloy is seen to have easy machinability, its high silicon content makes it slightly rough. The aluminum composition includes silicon (7.5-9.5%), Iron (2.0%), Copper (3.0-4.0%), Manganese (0.50%), Magnesium (0.10%), Nickel (0.50%), Zinc (3.0%), Tin (0.35%). It can also be called ADC10
A383
This is a common aluminum die casting alloy and its molten form fills better than that of 383. This makes it suitable for use when producing highly intricate parts. Good resistance to corrosion, excellent resistance to hot cracking, good anodizing, very good machinability are some of its winning properties. However, it is more expensive and less durable than A380. It possesses a higher level of silicon and lesser copper. Design engineers often use it as an alternative to A380 because it had enhanced corrosion resistance, it withstands hot cracking and has fluidity and strength compared to A380.
A413
An aluminum casting material with an amazing feature of pressure tightness. It is a perfect material for production in hydraulic cylinders. It is also good for die casting components that need a great level of detail. Moreover, it is suitable for applications that need enhanced strength. Some of its properties are; excellent resistance to corrosion, excellent resistance to hot cracking, good anodizing, and fair machinability. Because of its properties, it is best applied in industries such as aerospace, marine, automobiles and the manufacturing of air and gas cylinders.
B390
B390 is a common aluminum alloy that is composed of more than 11.7% silicon. It is higher than A380 and adds to its excellent wear resistance. The high silicon composition improves the alloy’s fluidity which allows for easy flow into complex molds. This process enables the casting of complex parts. Some of the advantages include resistance to corrosion, good resistance to hot cracking, fair anodizing, fair machinability, high hardness and good wear resistance, lightweight, excellent recyclability, and good finishing. Due to its fine properties, It is best applied in the military, automotive, lighting, construction and electrical industry.
518
518 has a gravity of 2.7 which makes it a light-weight structural metal. It has three primary constituents which it uses as a base for die casting alloys. Some of its advantages include excellent resistance to corrosion, poor resistance to hot cracking, excellent anodizing, excellent machinability, and good ductility. It is usually applied in escalator components, conveyor parts, hardware and marine accessories.
AC 46100
This die casting material is one of the alloys whose castability is excellent making it easier to use. Some of its advantages include; low ductility, low thermal conductivity, low temperature, medium strength at high temperature, fair resistance to corrosion, good machinability, good cast ability, fair polishing, low resistance to hot tearing, pressure tightness, weldability, low anodizing. This aluminum material is excellent for complex castings due to its good pressure tightness and weldability. It is also used for automobiles, railways, engines, and armory industries.
AC 46500
AC 46500 specific properties include; High ductility, low electrical conductivity, low melting temperature, strength-weight-ratio, low resistance to corrosion, good machinability, good castability, fair polishing, fair resistance to hot tearing, good pressure tightness, fair weldability and anodising, It is best used for automotive and electrical parts.
ADC12
This is an aluminum die casting material that contains a range of silicon from 9.6% – 12%. It is a common aluminum alloy among the ADC alloys. It has chemical properties of other metals such as copper and magnesium. This alloy has good thermal conductivity, electrical conductivity, excellent corrosion resistance with good oxidation resistance. The die cast aluminum material has enhanced strength and low density. It can also withstand high temperature. This aluminum alloy is applied in the production of cylinder accessories, sensor parts and automotive components.
ADC10
Another aluminum alloy for casting with good castability. It includes silicon material ranging from 7.5% – 9.5%. This aluminum die casting material offers good fluidity, light weight, great strength and good surface finishings. Because it was gotten from pure aluminum, it has good flexibility and is more malleable than other options like steel. The chemical composition of this aluminum alloy is a good combination that reduces machine downtime and breakage. It is used in producing automotives, sport accessories, electronic components, hand tools and transport equipments.
How to choose the right aluminum for casting
The accurate die casting process starts when you pick the best aluminum for your casting. Each casting process has its specificities. Therefore, you must choose the suitable aluminum alloy for casting, you have to note which features are peculiar to your process of choice. You should also be able to answer these three questions;
- What type of product are you making?
- What kind of atmosphere will it be exposed to?
- What kind of work are you expecting to be done by the die cast aluminum product?
Raidy Mold offers great services by choosing the right aluminum for your die casting. Below is a table that shows the aluminum die casting materials, their properties and price to show comparison between them.
| A360 | A380 | A383 | A413 | B390 | AC46100 | AC46500 | ADC 12 | ADC 10 | 518 | |
| Price | $2,807.06 | $2,956.84 | $1,400 – $2,000 | $0.3 – $50 per piece | $3,500 – $4,450 | $2,000 – $4,000 | $2,956 – $3,000 | $2,816.7 | $2,435 – $2,450 | $3,500 – $3,600 |
| Density | 2.63g/cm^3 | 2.71g/cm^3 | 2.74 g/cm^3 | 2.66 g/cm^3 | 2.8 g/cm^3 | 2.67 Kg/dm^3 | 2.9 g/cm^3 | 2.8 g/cm^3 | 2.71 g/cm^3 | |
| Melting Range | 557-596 °C | 540-595 °C | 516-582 °C | 578 °C | 580 °C | 565-585 °C | – | 516 – 582 °C | 566 °C | 535 – 621 °C |
| Thermal conductivity | 113 W/(m. K) | 96.2W/(m. K) | 96.2 W/(m. K) | 121 W/(m. K) | 130 W/m. K | 120 – 130 W/(m. K) | 100W/m. K | 92.0 W/(m. K) | 96 W/(m. K) | 96.2 W/(m. K) |
| Electrical conductivity | 29% IACS | 23%IACS | 23% IACS | 31% IACS | 27%IACS | 14 – 18% IACS | 26%IACS | – | 23.0% IACS | |
| Ultimate Tensile Strength | 320 MPa | 320 MPa | 310 MPa | 290 MPa | 320 MPa | 240 MPa | 270 MPa | 331 MPa | 324 MOa | 310 MPa |
| Yield Strength | 170 MPa | 160 MPa | 150 MPa | 130 MPa | 250 MPa | 140 MPa | 160 MPa | 165 MPa | 160 MPa | 193 MPa |
| Hardness | 75 BHN | 80 BHN | 75 BHN | 80BHN | 120 BHN | 80 BHN | 91 BHN | 85 BHN | 80 BHN | 80 BHN |
| Fatigue Strength | 120 MPa | 140 MPa | 145 MPa | 130 MPa | 170 MPa | 60-90 MPa | 110 MPA | 140 MPa | 137 MPa | 160 MPa |
| Shear Strength | 180 MPa | 190 MPa | – | 170 MPa | – | – | – | 199 MPa | 190 MPa | 205 MPa |
| Elongation | 2.5%(In 51 mm) | 3.5% (In 51 mm) | 3.5%(In 51 mm) | 3.5% in 50 mm | 0.88% | 1% | 1% | 2.5% | 3.50 in 50 mm | 5.0% |
| Machinability | – | – | – | 30% | – | – | – | 50% | 50% | 90% |
Conclusion
This article has explored the definition, process, and the benefits of aluminum die casting. It also discussed the application of these aluminum alloys in various industries. Furthermore, this article projected the prices of these alloys and what they are most suitable for. Moreover, it expounded on the chemical composition and the die cast aluminum material properties with the inclusion of the physical and technical properties of the aluminum casting material. Raidy mold is a global mold maker in China that offers expert services in aluminum die casting. With the strict supervision of our design engineers, you are assured to get the best accessories for your application. Contact Raidy Mold today!
