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Aluminum Pressure Die CastingSteel Investment Castings - Lost Wax Castings - All Popular Metal Casting Alloys |
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Aluminum pressure die casting is the fastest method for mass production of precision parts. This die casting technique has a history of more than 150 years and the mass production of die casting components began around the 1900s. Aluminum pressure die casting is used to produce light weight, thin wall components of complex shapes, which demand stability at high temperatures and good corrosion resistance. The die casting process involves the injection of molten metal into the die (mold) at high pressure. A high quality steel die is used for this process and the pressure varies from 5ksi to 10ksi (35Mpa to 69Mpa). The (cold chamber) temperature is set at 300° F to 500°F (150° to 260°C), well below the solidification temperature, to enable quick solidification of the casting. The high pressure and high velocity filling of the cavity ensures uniform solidification of the casting. The hot chamber is used for metals with low-melting points such as zinc and copper. | |||||||||
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The thin wall components produced by aluminum pressure die casting process have a smooth surface finish, superior mechanical qualities, and excellent dimensional precision. Aluminum pressure die casting parts are used in a wide range of applications from lawn mowers to aircrafts and submarines. About 85% of aluminum alloy casting is with 380.0 or similar silicon-copper alloys of aluminum. Alloys 380.0, A380.0, 360.0, 413.0, and 518.1 are used for specific applications. Alloys 518.0, 360.0 and 413.0 have less copper content and higher levels of corrosion resistance. These alloys have a good fluidity and are free from hot shortness and are easy to cast. There are three types of die casting machines: A single cavity machine that produces a single component; multiple cavity machine for producing a number of identical components; and the unit die that produces different parts at the same time. There are definite advantages to aluminum pressure die casting as it supports mass production of a wide range of components, with high levels of dimensional accuracy and stability. The parts have a higher strength to weight ratio and ductility. | |||||||||
For more information about Aluminum Pressure Die Casting |
Reduces Labor Costs — This speed and efficiency in producing finished parts is its greatest advantage. The quick cooling of die-castings helps to keep the production time from less than a second to a few minutes. As this process produce components of smooth surface finish, no machining or detailing is needed, reducing labor costs and finishing time. Since the metal is applied to mold under high pressure, the risk of entrapped air is high. Heat treatment of aluminum pressure die casting parts is avoided to reduce the chances of blistering on the surface of the parts. Occasional metallurgical treatment ensures stability of the parts. |
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