ALUMINUM DIE CASTING
Aluminum die casting alloys are lightweight and possess high dimensional stability for complex part geometries and thin walls. Aluminum withstands good corrosion resistance and mechanical properties as well as high thermal and electrical conductivity, making it a good alloy for die casting. Low-density aluminum metals are essential to the die casting industry. The Aluminum Die Casting process retains a durable strength at very high temperatures, requiring the use of cold chamber machines. The molten metal is still contained in an open holding pot which is placed into a furnace, where it is melted to the necessary temperature. The open holding pot is kept separate from the die casting machine and the molten metal is ladled from the pot for each casting because these high temperatures would damage the normal pumping system. The pressure requirements for cold chamber castings are typically higher than those of hot chamber die castings.
THE ALUMINUM DIE CASTING PROCESS
The casting process implements a steel mold often capable of producing tens of thousands of castings in rapid succession. The die must be made in at least two sections to permit removal of castings. The casting cycle begins with the two die halves are clamped tightly together by the die casting press. Molten aluminum is injected into the die cavity where it solidifies quickly. These sections are mounted securely in a machine and are arranged so that one is stationary while the other is moveable. The die halves are drawn apart and the casting is ejected. Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting. Most machines use mechanisms actuated by hydraulic cylinders to achieve locking. Others use direct acting hydraulic pressure. Die casting machines, large or small, very fundamentally only in the method used to inject molten metal into the die.
WHAT ARE THE ADVANTAGES OF ALUMINUM DIE CASTING?
There are many reasons aluminum is the most commonly cast non-ferrous metal in the world. As a lightweight metal, the most popular reason for utilizing aluminum die casting is that it creates very lightweight parts without sacrificing strength. Aluminum die cast parts also have more surface finishing options and can withstand higher operating temperatures than other non-ferrous materials. Aluminum die cast parts are corrosion resistant, highly conductive, have a good stiffness and strength-to-weight ratio. The aluminum die casting process is based on rapid production that allows a high volume of die casting parts to be produced very quickly and more cost-effectively than alternative casting processes. Aluminum die casting has become the favored option for buyers worldwide. Characteristics and Advantages of Aluminum Die Castings include:
◆ Lightweight and Durable
◆ Good Strength-to-Weight Ratio
◆ Great Resistance to Corrosion
◆ Excellent Electrical Conductivity
◆ Fully Recyclable and Reusable in Production
ALUMINUM DIE CASTING PRODUCT SEGMENTATION
The popularity of aluminum has expanded to many applications around the world today, driving competitive market shares primarily for its distinctive features such as lightweight; corrosion resistance, high electrical and thermal conductivity, high stability for complex shapes and high tensile strength. The transportation sector is the largest end-use segment for this industry. The increasing emission laws by the government regulatory authorities, along with consumer demand for a higher fuel-efficient vehicle is developing a necessity for aluminum casting. An example of increased operations for the industry includes the replacement of iron and steel components in a vehicle with lightweight high-quality aluminum in order to increase the fuel efficiency. The Aluminum die cast product is ideal for electronic connectors and housings die to its excellent electrical performance and shielding properties, even in high-temperature environments.
Another sector regarding the aluminum die casting demand includes building and construction in developing economies particularly in the Asia Pacific region. Aluminum Die Casting is associated with the creation of products including windows, cladding, curtain walling, prefabricated buildings, shop partitions, and fittings. Also, aluminum die casting products are used in aerospace operations or airplanes all around the world. The aerospace industry wants to produce a more dense and larger quality product at lower costs for these air-frame components as aircraft continue to grow in size along with population rates.
Aluminum Die Casting Applications:
Aluminum castings improve automotive fuel efficiency by contributing to weight saving requirements
Aluminum is used in a broad range of networking and infrastructure equipment in the telecom and computing industries because RF filter boxes and housings require heat dissipation
In handheld devices, aluminum castings provide EMI/RFI shielding, rigidity, and durability with minimal weight
Because of aluminum’s excellent electrical performance and shielding properties, even in high-temperature environments, die cast aluminum is ideal for electronic connectors and housings
Recycling Aluminum Die Castings
Did you know that over 95 percent of aluminum castings made in North America are made of post-consumer recycled aluminum?
There is very little functional difference between primary (extracted or pure) and secondary (recycled) Recycling Aluminum Die Castingsaluminum when it refers to die casting. Secondary aluminum alloys are derived from mixing and melting pure aluminum with other materials such as magnesium, iron, and copper. The use of pure aluminum in casting is quite rare due to the cost of extraction. The ease of use in die casting combined with lighter weight and durability make aluminum alloys a top choice for designers from nearly any industry.
Secondary aluminum is more economical to produce than primary aluminum because it only requires 5 percent as much energy to produce. Most of the energy consumption in aluminum die casting is used to heat and re-melt the metal during fabrication.