Views: 2 Author: Site Editor Publish Time: 2023-01-30 Origin: Site
Multiple manufacturing processes are available for producing any part. But usually, one process has the edge over the other.
In this case, Kaiao believes that the die-casting process is the most suitable process for aluminum and lightweight products.
There are many reasons for die cast being the go-to for industries. Still, the main reason is its ability to use aluminum (thin metal sheet) to produce dimensionally stable and complex shapes with thin walls.
You may need in-depth information about this process. Read through to learn everything about it before taking further steps.
The aluminum die-cast process is a procedure for making metal parts from aluminum.
It involves using a pre-prepared steel mold with two halves in the shape of the intended product.
The aluminum material is then heated at a very high temperature and forced under high pressure into the mold cavity, closed, and left to solidify.
When it is brought out, it takes the shape of the mold. The steel mold is reusable and capable of creating many other products.
The aluminum melting process usually takes place in the casting machine's cold chamber due to the molten metal's extreme heat, which can damage the device.
Hence, the process of producing the part can begin after separating the melting pot containing the molten metal.
Usually, little to no surface treatment is needed after the process because the product comes very fine and smooth.
Why is aluminum die-cast the go-to for many industries?
Aluminum is arguably the most casted non-ferrous metal in the world. As such, you can understand the popularity of the die-cast method in industries today.
Regardless, there are other unique features of aluminum and the die-casting process that make it stand out.
Let's look at what it brings to the table below:
● Ability to create very complex parts.
● Surface finishes are excellent and require minimal treatment before being marketed.
● The raw materials are less expensive.
● It has an excellent tensile strength
● The range of alloys is vast, each containing specific characteristics.
● The dimensional tolerance is high.
● A thin wall part with high strength can be produced.
● Longevity
The range of aluminum alloys used for this process is relatively wide. For you to maximize your result, you need first to pick the appropriate alloy.
Below is a list of the appropriate ones and details on the most common.
● A380
● A360
● A390
● A413
● ADC-1
● ADC-12
This alloy seems to have the best product quality casting process. Its application ranges from chassis of electronics and automobiles, engine brackets, household utensils and furniture, power tools, gearbox cases, etc.
The standout feature of this alloy is its excellent pressure tightness and high corrosion resistance. Its application ranges from oil pans for automobiles, 5G communication boxes, controller shells for cars, etc.
For an application that requires high wear resistance or excellent rigidity, alloy 390 is implemented. An example is engine block automotive.
Below is a detailed laydown of the properties of aluminum alloys.
They are:
● Excellent strength-to-weight ratio
● High resistance to corrosion
● Reusable and recyclable.
● High thermal conductivity.
● Light in weight
● Incredible rigidity
● High electrical conductivity
It is not without proof that aluminum die-cast produces parts with smooth and fine finishing. But surface finishing is more than just improving smoothness. A lot can be done to the mechanical and aesthetic features as well.
Hence, surface finishing is also applied in this process. The basic ones are:
Anodizing is a surface finishing that improves the durability and corrosion resistance of aluminum die-cast parts. It is less expensive and the go-to in terms of a cheap method.
It consists of an oxide layer protective film over the metal. The oxide is an insulator because it consists of ceramic which makes the die-cast products non-conductive.
This is somewhat similar to anodizing. It involves laying a film over the die-casted product but is electrically conductive.
It is applied by spraying, brushing, dipping, etc.
Manufacturers have greatly embraced this surface finish, although it is a little tricky. It is done under intense temperatures.
The resultant effect is a glossy, colorful, and scratch-resistant finish. This is perhaps the reason for its popularity among manufacturers.
The market value of this manufacturing process keeps growing. With many requirements attached to modernization, many applications and industries are going after the procedure's benefits.
Below are the main applications of the process today:
A compatible modern-day vehicle is lightweight and durable. That is precisely what aluminum die-casting ensures.
The automotive industry is littered with aluminum die-casting procedures, ranging from interior to exterior.
Aluminum possesses the quality needed in office furniture, seats, cushions, etc. These characteristics include excellent strength-to-weight ratio, corrosion resistance, and less expensiveness.
Construction processes like the building of bridges, skyscrapers, etc., make use of aluminum die-casting.
The materials for the building purpose, like window frames, roofs, doors, etc., are all applications of the process.
The significant success of electronic industries over the decades has aluminum die-cast to praise as part of their success. Aluminum features are essential in making many products like consumer goods, smartphone battery components, 5G network components, etc.
Aerospace industries use aluminum die-cast for making parts like fuel system components, cargo loading housing, engine piston heads, detention rings, lighting fixtures, etc.
There are essential things to bear at the back of your mind when designing aluminum die-cast products for complete satisfaction. They are:
Make sure the mold design can incorporate the molten aluminum you are going to put inside.
It is necessary to ensure that the mold design is exactly how you intend the product to look, as the molten metal takes the shape of the mold. Also, the parting line should be accurately accounted for to ease the operation.
The point and amount of the injection also matter. A production that the molten metal solidifies before it reaches every angle of the mold will be better off with different injection points at various locations.
It can prove most beneficial when you maintain a consistent wall thickness for effortless flow and better results, either with little or high thickness.
Aluminum is an essential metal in the industrial world, and aluminum die-cast is here to maximize the metal's qualities. You can use aluminum die-cast to improve your business needs or facilitate progress.
Reach out to us for quality aluminum die-cast service. Kaiao is a reputable company, and we have satisfied the international community for over a decade.
Get satisfied service in the fastest time frame now!
