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Aluminium Die Casting Companies Produce High Quality Metal Parts Through Die Casting
Die casting is a manufacturing process that has been used for decades to produce high quality metal parts and products. One of the most common metals used in die casting is aluminium due to its lightweight properties, high strength, corrosion resistance, electrical conductivity and ease of fabrication. Aluminium die casting is ideal for high volume production and provides precise dimensional accuracy and repeatability for complex products and components. Companies that specialize in aluminium die casting utilize state-of-the-art die casting equipment and techniques to deliver strong, durable aluminium parts catered to their clients' exact specifications and requirements.
The Die Casting Process
The die casting process starts with melting aluminium ingots and forcing the molten aluminium at high pressure into steel dies. The moulds and dies are machined to the shape and contour of the desired part and can be designed to produce complex geometries with tight tolerances. The molten aluminium completely fills the die cavity and rapidly cools and solidifies into the final part shape. The entire process is automated using machines that control the timing, temperature and speed at which the molten aluminium is injected. Once cooled and hardened, the cast aluminium parts are mechanically ejected from the dies and trimmed of any excess material or flash. Secondary finishing operations such as surface treatments or coatings can then be applied to give the parts a finished appearance.
Benefits of Aluminium Die Cast Parts
There are many reasons why die casting has become the preferred method for producing high volumes of aluminium parts and products:
- Excellent dimensional precision and tolerance control - die cast parts can be held to tolerances as tight as +/- .002 inches.
- Smooth cast surfaces with fine detail resolution - die cast parts replicate even the finest surface details of the mould cavity.
- Versatility - complex and intricate shapes can be die cast that would be difficult or impossible with other methods.
- Thin walls and sections possible - aluminium parts can have walls as thin as 0.030 inches while maintaining strength.
- Minimal secondary machining - die cast aluminium parts often require little or no additional finishing after being ejected from the dies.
- Superior strength-to-weight ratio - aluminium die castings are stronger than plastic injection moulded parts while having less weight.
- Rapid production rates - cycle times for producing die cast aluminium components can be in seconds.
With these advantages, it is easy to see why aluminium die casting has become the technique of choice for high volume production across many industries including automotive, business machines, electronics and aviation. Companies that provide aluminium die casting services have the capabilities to deliver cast aluminium parts and products to meet nearly any specification.
Applications of Aluminium Die Cast Parts
The versatility of aluminium die casting allows components to be manufactured with the necessary properties for a wide array of applications:
Automotive - Die cast aluminium parts are found throughout vehicles including engine blocks, cylinder heads, transmission housings, brackets, pumps, valve bodies and more. Aluminium provides the lightweight strength needed while withstanding under-hood temperatures.
Aerospace - Aluminium is the predominant metal used in aircraft for engine and structural components where lightweight and strength are imperative. Die cast parts provide the complex shapes and thin walls needed in aerospace designs.
Electronics - Die casting aluminium creates precision enclosures, frames, shields and heat sinks to house sensitive electronics and dissipate heat. Aluminium offers excellent electrical conductivity and EM shielding.
Medical - Die cast medical equipment components must withstand repeated sterilization procedures. Aluminium has high biocompatibility and can be repeatedly autoclaved without failure.
Telecommunications - Aluminium die castings have high radio frequency shielding capabilities, making them suitable for antennas, waveguides, base station enclosures and more.
Military and Defense - Rugged aluminium die cast parts can survive shock, vibration, chemicals and temperature extremes often encountered in military and defense technology.
Business Machines - Precise and smooth die cast aluminium components make up housings for computers and business machines as well as internal parts like levers, cams, gears and mounting plates.
Hardware and Appliances - Aluminium die castings provide the durable and corrosion-resistant exterior casings for power tools, locks, handles and appliances of all types.
Finding the Right Aluminium Die Casting Company
With so many vital products relying on die cast aluminium components, choosing the right die casting company is crucial. Here are tips for selecting a qualified aluminium die casting supplier:
- Make sure the company has expertise in aluminium die casting including alloy knowledge, tooling design and quality processes. Ask about their capabilities and experience.
- Evaluate their production capacity and lead times. Can they meet your volume requirements and schedule?
- Examine the size and condition of their die casting machinery. Well maintained equipment is vital for quality results.
- Consider their other value-added services like CNC machining, finishing, polishing, plating, coating and assembly.
- Review their quality certifications like ISO or AS standards to confirm their capabilities.
- Request to audit their manufacturing facility and speak with knowledgeable staff.
- Ask for customer references and samples of die cast aluminium products they have produced.
The right aluminium die casting company partner can deliver quality, innovative solutions and help optimize a component's design for casting. With die casting being a key manufacturing process for high volume production across many vital industries, choosing an established and reputable die casting firm is an important supply chain decision. Companies with proven expertise in aluminium die casting processes and procedures will deliver reliable and consistent results using this versatile high volume metal forming technique. CNC Milling CNC Machining