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Aluminum alloy die-casting products are mainly used in industries such as electronics, automobiles, motors, home appliances, and some communication industries. Some high-performance, high-precision, and high toughness high-quality aluminum alloy products are also used in industries with high requirements such as large aircraft and ships. The main use is still in the parts of some instruments.

Industrial Die Casting- Ultimate FAQ Guide

The process flow of aluminum alloy die-casting mainly includes steps such as mold design, aluminum alloy melting, injection molding, cooling solidification, demolding, trimming, and surface treatment. Now let's have a detailed understanding of the relevant knowledge of aluminum die-casting:

• Electronics

• Automobiles

• Motors

• Home appliances
  

What is die-casting aluminum?

Casting is a process of metal smelting and processing, usually using the gravity of the metal to cast in the mold. But 'aluminum die-casting' is not done by gravity, but by applying a certain amount of pressure. It's a bit like 'injection molding'. But it has a set of high-tech core pulling, cooling and other systems. Overall, the material is delivered to the mold cavity to be cast through a centralized "injection" inlet, forming the part.

What are the process characteristics of die-casting aluminum?

High pressure and high-speed filling die cast aluminum molds are two major characteristics of die cast aluminum. Its commonly used injection pressure ratio ranges from thousands to tens of 

thousands of kPa, and even up to 2 × 105kPa. The filling speed is about 10-50m/s, and sometimes it can even reach over 100m/s. The filling time is very short, usually within the range of 0.01 to 

0.2 seconds.

advantage

1. Good product quality: The dimensional accuracy of castings is high, generally equivalent to levels 6-7, and even up to level 4; Good surface finish, generally equivalent to 5-8 grades; 

The strength and hardness are relatively high, and the strength is generally increased by 25-30% compared to sand casting, but the elongation is reduced by about 70%; Stable size and good 

interchangeability; Die-casting aluminum thin-walled complex castings. For example, the current minimum wall thickness of zinc alloy die-casting aluminum parts can reach 0.3mm; Aluminum 

alloy castings can reach 0.5mm; The minimum casting aperture is 0.7mm; The minimum pitch is 0.75mm.

2. High production efficiency: High machine productivity, such as the domestic J-III3 horizontal cold air die-casting aluminum machine, which can die-cast aluminum 600-700 times per eight 

hours on average, and the small hot chamber die-casting aluminum machine, which can die-cast aluminum 3000-7000 times per eight hours on average; Die-casting aluminum molds have a long 

lifespan, with a pair of die-casting aluminum molds and die-casting aluminum bell alloys, the lifespan can reach several hundred thousand times, or even millions of times; Easy to achieve 

mechanization and automation.

3. Excellent economic effect: Due to the advantages of precise size and smooth surface of die-casting aluminum parts. Generally, it is used directly without mechanical processing, or the processing 

volume is small, which not only improves the metal utilization rate but also reduces a large number of processing equipment and working hours; The casting price is cheap; Combination die-casting 

aluminum can be used with other metal or non-metallic materials. It saves both assembly time and metal.

Shortcoming

1. When using die-casting aluminum, due to the high speed of liquid metal filling the mold cavity and unstable flow state, the general die-casting aluminum method is used. 

The casting is prone to gas pores and cannot undergo heat treatment;

2. For castings with complex concave surfaces, die-casting aluminum is more difficult

3. High melting point alloy (such as copper and Ferrous), low life of die cast aluminum mold;

4. It is not suitable for small-scale production, mainly due to the high manufacturing cost of die-casting aluminum molds, high production efficiency of die-casting aluminum machines, and 

uneconomical small-scale production.

The Process Flow of Aluminum Die Casting

1. Mold design is a key link in aluminum alloy die-casting, which directly affects the quality and cost of the product. Mold design needs to consider factors such as product shape, size, 

wall thickness, structure, as well as physical properties such as fluidity and shrinkage of aluminum alloy. After the mold design is completed, mold manufacturing and debugging are required.

2. Aluminum alloy melting. The aluminum alloy material used in aluminum alloy die casting is usually aluminum alloy ingots with special formulas, which require melting and insulation treatment. 

During the melting process, it is necessary to control parameters such as furnace temperature, aluminum alloy composition, and gas content to ensure the quality and stability of aluminum alloys.

3. Injection molding

Injection molding is the core process of aluminum alloy die-casting, which requires the use of a die-casting machine to inject molten aluminum alloy into the mold. Injection molding requires 

controlling parameters such as injection speed, pressure, and temperature to ensure the integrity and uniformity of the aluminum alloy filling mold.

After cooling and solidification injection molding, the mold needs to be placed in cooling water for cooling and solidification. The cooling time needs to be adjusted based on factors 

such as product size and wall thickness to ensure product quality and stability.

After demolding, cooling and solidification, it is necessary to open the mold and remove the aluminum alloy product from the mold. Demolding requires attention to the surface 

quality of the product and the maintenance of the mold to ensure quality and stability for the next use.

6. Finishing and surface treatment

After demolding aluminum alloy products, it is necessary to carry out trimming and surface treatment. Trimming includes processes such as removing burrs, cutting excess materials, 

and polishing to ensure the size and appearance quality of the product. Surface treatment includes painting, electroplating, anodizing, and other processes to improve the corrosion resistance 

and aesthetics of the product.

Application Fields of Aluminum Die Casting

Aluminum alloy die-casting is widely used in fields such as automobiles, aviation, electronics, and machinery. In the automotive field, aluminum alloy die-casting can be used to manufacture 

components such as engine cylinder heads, crankcases, suspension systems, etc., in order to improve the lightweight and fuel economy of automobiles.

In the aviation industry, aluminum alloy die-casting can be used to manufacture aircraft engine casings, wings, and other components to improve the performance and safety of aircraft. 

In the electronic field, aluminum alloy die-casting can be used to manufacture Mobile phone case, computer radiator and other components to improve the beauty and heat dissipation 

performance of products.

In the field of machinery, aluminum alloy die-casting can be used to manufacture components such as toolboxes and machine casings to improve product durability and aesthetics. 

Aluminum alloy die-casting is an efficient and precise casting process with broad application prospects and market demand. With the continuous progress of technology and technological 

innovation, aluminum alloy die-casting will be applied and developed in more fields.

What equipment does die-casting aluminum require?

With the continuous development and progress of modern technology, die-casting equipment is playing an increasingly important role in industrial production. Aluminum alloy products are 

increasingly popular among consumers, and aluminum alloy die-casting equipment is one of the important tools for producing these products.

There are many types of die-casting equipment in the market, and there are differences in the selection of die-casting equipment for different raw materials, scales, and parts requirements. 

When selecting a die-casting factory, the purchaser also needs to analyze the actual situation and choose the most suitable method for themselves.

Die casting equipment can be divided into the following categories based on different metal materials and process requirements:

1. Cold Chamber Die Casting Machine: A cold chamber die casting machine is a process in which a certain amount of molten metal is poured into an unheated closed injection chamber (cold chamber), 

and then a piston is used to press the metal solution into the mold, which is cooled and solidified under a certain pressure to form the final part or product.

Compared to hot chamber die-casting machines, cold chamber die-casting machines are suitable for casting high melting point alloys such as aluminum, magnesium, copper, etc., as these 

materials have a high melting point and cannot remain liquid at room temperature. Cold chamber die-casting machines typically include components such as injection systems, mold locking 

systems, and electrical control systems.

2. Hot chamber die-casting machine: suitable for die-casting low melting point non-ferrous alloy parts such as zinc and lead, and widely used in industrial departments such as automobiles, 

motorcycle accessories, instruments and meters, daily hardware, and household appliances. This equipment is controlled by an industrial grade microcomputer and can set die casting process 

parameters on the human-machine interface. It has the characteristics of labor-saving, time-saving, and convenient operation and maintenance.

3. Semi solid die-casting machine: Semi solid die-casting machine is a production process that involves die-casting metal alloys in a semi solid state. Compared with traditional die-casting methods, 

semi-solid die-casting technology can effectively improve the mechanical properties, surface quality, and dimensional accuracy of metal parts, making it suitable for manufacturing high-strength 

components with complex shapes. Its working principle is to evenly distribute the grains in the molten metal, and then control the temperature of the molten metal when it transitions to a semi 

solid state. The metal is pressed into the mold using a die-casting machine and processed to obtain the desired product or part. Semi solid die-casting machines generally include important 

components such as injection systems, mold locking systems, and electronic control systems.

The above are commonly used types of die-casting equipment, and different die-casting machines are suitable for different workpieces and materials. Choosing the appropriate die-casting equipment 

plays a crucial role in improving product quality and production efficiency.

In addition, there are different classification methods such as vertical die-casting machines and horizontal die-casting machines.

Vertical die-casting machine is a die-casting equipment that adopts a vertical structure. Its working method is to inject molten metal into the die-casting chamber from above, and then remove the 

parts from below after die-casting molding. The vertical die-casting machine has the characteristics of compact structure and convenient operation.

The horizontal die-casting machine is opposite to the vertical die-casting machine in that it operates in a horizontal position. Horizontal die-casting machines have the characteristics of high 

production capacity and high degree of automation, and are also widely used in the production of components in fields such as furniture, home appliances, electronics, aerospace, etc.