Aluminum die casting is a manufacturing process where the molten aluminum alloy is forced into a mold under high pressure to create parts. Once the molten metal takes on the shape of the intended product and solidifies, the mold is is opened, and then the part is ejected. The process allows for the mass production of complex metal parts with close tolerances, and robust mechanical properties.

Echofast is a leading aluminum die casting mold manufacturer in Taizhou, Zhejiang, China., which is the hometown of mold. We promise to make high-quality products on demand while providing a fast and easy manufacturing experience.

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Applications of Aluminum Die Casting

Aluminum die casting is not only lightweight, but also possesses high dimensional stability. It works well for complex part geometries. The process is generally used in a wide range of applications in Echofast, including:

  • Some automotive components
  • Communication equipment housings
  • Electronics housings
  • Machine tools
  • Security equipment casings (shells)
  • Light fittings and housings

used on the die casting machines

LK die casting machines

YIZUMI die casting machines

Xinjiasheng die casting machines

Echofast Custom Service-Aluminum Die Casting

Aluminum die casting is a perfect choice for creating high volumes of relatively lightweight but complex parts without sacrificing strength. With a combination of expertise, state-of-the-art facilities, and comprehensive services, Echofast can manufacture aluminum die casting molds and offer comprehensive services with great performance, durability, and efficiency. The aluminum die castings of one to five millimeters are available in Echofast with different aluminum alloys, which can reach the T6 state. They are produced with improved mechanical properties like good hardness and strength. At the same time, the air tightness of the die casting parts meets the requirements of consumers and ensures no blistering in the welding area, achieving optimal performance.

Echofast R&D Capabilities

Die Casting Mold Design and Manufacturing

Echofast specializes in the design and fabrication of high-quality molds customized to your exact specifications. With close cooperation with experts, we provide consultation and design assistance throughout the process by leveraging advanced CAD/UG/AnyCasting software and our expertise.

Draft is the degree to which a mold core can be tapered. To smoothly eject the casting from the die, a precise draft is needed. However, the draft is not constant and varies according to the angle of the wall, and a host of characteristics can affect the process, including the type of molten alloy used, the shape of the wall, and the depth of the mold. Mold geometry is another factor that influences drafts. Generally, tapering is needed for untapped holes because of the risk of shrinkage. Likewise, inner walls need more drafting than outer walls because inner walls can also shrink.

Fillets are concave junctions used to smooth angled surfaces. Since sharp corners can hinder the casting process,many molds can create fillets and reduce the risk of production errors with fillets. Fillets can be added almost anywhere on the mold except the parting line.

The parting line, or parting surface, is used to join different sections of the mold together. Material can seep through the gap between the mold pieces when the parting line is wrongly positioned or is deformed because of work strain. This can result in non-uniform molding and excessive seaming.

Bosses are die-cast knobs, which serve as stand-offs or mounting points in the design of the mold. To make sure that the wall thickness in a molded product is uniform, manufacturers usually add a hole to the internal structure of the boss. It is difficult to fill deep bosses with metal, so filleting and ribbing may be a necessary choice on this issue.

Die casting ribs can help improve material strength in products that lack the desired wall thickness. With the support selective rib placement,the chance of stress cracking and non-uniform thickness can be reduced. Selective rib placement also contributes to decreasing product weight and improving fill capabilities.

Having holes or windows in a die casting mold directly impacts the ejection mechanism of a completed mold and allows for the creation of substantial drafts. Features like flashovers,overflows,and cross feeders are required to prevent unwanted casting or poor material flow.

Manufacturers usually include brand names or product logos in the mold design of die casting products. Despite the fact that symbols do not make the die casting process complex,they can influence the cost of production. A raised logo or symbol requires additional molten metal volume for each manufactured part,adding to the costs of production. In contrast,a recessed symbol requires less raw material,reducing costs.

Prototype Development

Our prototyping process facilitates iterative design enhancement and validation, guiding you from initial concept to prototype realization swiftly and economically. It allows for thorough testing of design functionality and feasibility before proceeding to full-scale production,. This can mitigate risks and ensure the final mold meet your expectations. In this phase, the most suitable aluminum alloy for the prototype can be selected, with a lot of factors taken into consideration like strength, durability, and thermal conductivity.

High-Volume Production

With the advanced manufacturing capabilities and streamlined processes, Echofast can produce thousands or millions of parts with consistence and precision. We provide you with cost-effective production solutions, utilizing advanced die casting machines and implementing rigorous quality control procedures at every stage of production to ensure consistent and high-quality results.

Surface Finishing

Echofast offers a range of surface finishing options to greatly improve the performance and aesthetics of the aluminum die castings, and extend the service life. Our finishing services include powder coating, shot blasting, painting, plating, passivation and more.

Need affordable mold services?

Price is a challenge in die casting, especially for molds. Echofast offers highly competitive prices (10% below market price), making our services affordable for small manufacturers. You can talk to our mold experts, discuss your product idea, discover its manufacturability, and get the sample.

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Types of Aluminum Die Casting

Cold chamber die casting, also referred to as cold casting, involves melting metal in a separate furnace and subsequently pouring the molten metal into an unheated chamber for injection into the mold under high pressure. It is the preferred die casting process for metals with higher melting temperatures, such as aluminum, magnesium, and copper alloys. It is ideal for producing high-quality aluminum parts with tight tolerances, excellent dimensional accuracy and surface finish. This results from the characteristics of aluminum alloys and the requirements of the die casting process.

Higher Melting Point: Aluminum alloys generally have higher melting points compared to materials like zinc or magnesium, making cold chamber die casting more prevalent in aluminum die casting operations.

Alloy Properties: Specific aluminum alloys are conducive to hot chamber die casting due to the presence of alloying elements capable of lowering the melting temperature. However, the majority of aluminum alloys utilized in die casting typically require higher melting temperatures, thus establishing cold chamber die casting as the preferred method. Cold chamber die casting affords superior command over the casting process, which ensure consistent quality and dimensional accuracy of aluminum parts.

A Diverse Range of Part Dimensions and Configurations:The cold chamber die casting process provides flexibility in producing larger and intricate aluminum parts, free from worries regarding premature solidification or constraints imposed by hot chamber die casting machinery. This technique accommodates a diverse range of part dimensions and configurations, rendering it applicable across multiple industries and applications.

Materials of Aluminum die casting

Common materials used in aluminum die casting include various aluminum alloys that are specifically formulated for die casting processes. To meet the unique needs of different die casting projects, Echofast selects aluminum alloys carefully based on the specific requirements of the application, including mechanical properties, surface finish, dimensional accuracy, and cost considerations. We offer the most commonly used aluminum die casting alloys, including:

AlloyCorrosion resistanceResistance to hot crackingAnodizingMachinabilityCommon applications
 ADC12 ExcellentGoodDifficultGood Automotive applications, electrical components, and consumer goods.
A380FairVery goodGoodGoodWorkbench vises and other hand tools, gear cases, lawnmower housings
A360ExcellentExcellentGoodGoodInstrument cases, irrigation system parts, outboard motor parts, hinges
383GoodExcellentGoodVery goodEngine brackets, cylinder head covers, appliances, furniture, power tools
A413ExcellentExcellentGoodFairOutboard motor pistons, dental equipment, street lamp housings
B390FairGoodFairFairPistons, blocks, manifolds, and cylinder heads for internal combustion engines, brake cylinders
518ExcellentPoorExcellentExcellentArchitectural castings, conveyor parts, marine and aircraft hardware fittings

For example, ADC12 is the most commonly used material for aluminum die castings due to its good corrosion resistance, thermal conductivity and low cost.

A380 is the perfect jack-of-all-trades, offering a good combination of casting and product properties, and is the most commonly specified alloy for casting a wide variety of products.

A360 offers excellent corrosion resistance, pressure tightness, and very good fluidity when molten.

Advantages Of Aluminum Die Casting

Aluminum die casting has numerous benefits. These advantages are listed below:

  • Lightweight: Aluminum, characterized by its lightweight nature and exceptional strength-to-weight ratio, emerges as an optimal choice for industries prioritizing weight reduction, notably the automotive and aerospace sectors. Die cast aluminum components deliver robustness and endurance without adding unnecessary weight.
  • High Dimensional Accuracy: Aluminum die casting is ideal for the production of complex parts with tight tolerances and precise dimensions. The die casting process delivers outstanding repeatability and consistency, thereby guaranteeing uniformity throughout extensive production cycles.
  • High Strength and Durability: Aluminum die casting facilitates the fabrication of intricate parts with excellent mechanical properties, including high strength, stiffness, and impact resistance. The manufacturing process is suitable for demanding applications where robust and durable components are required.
  • Corrosion Resistance: Aluminum naturally forms a thin oxide layer on its surface, which offers inherent protection against corrosion. Moreover, surface treatments like anodizing or powder coating can be employed on aluminum die cast parts to improve corrosion resistance in harsh environments.
  • Excellent Thermal Conductivity: Aluminum has excellent thermal conductivity properties, facilitating efficient heat dissipation in applications such as electronic enclosures, heat sinks, and automotive parts. This feature minimizes the risk of overheating and contributes to prolonged component lifespan.
  • Versatility: Aluminum die casting provides versatility in design and production, making it suitable for the creation of complex shapes and intricate details. The process caters to a wide range of part sizes and geometries, allowing for applications across diverse industries.
  • Cost-Effective Production: Aluminum die casting is a highly efficient and cost-effective manufacturing process, especially tailored for large-scale production. Its high-speed production capabilities reduce labor and tooling costs per part, ultimately yielding substantial cost savings.
  • Environmental Sustainability: Aluminum is recyclable, contributing to its minimal environmental impact. Through the die casting process, material waste is minimized, and the carbon footprint of manufacturing is further reduced by recycling aluminum scrap.

Available Aluminum Die Casting Finishes

Alternatives to Aluminum Die Casting

Mold Making Services FAQs

The lead time for producing aluminum die castings can vary depending on factors such as part complexity, quantity, and specific requirements. Generally, lead times range from a few weeks to several months, with larger production volumes often requiring longer lead times.

Aluminum die casting can achieve tight dimensional tolerances, typically ranging from ±0.005 to ±0.020 inches, depending on the part design and casting process capabilities. Tighter tolerances may be achievable with additional machining or secondary operations.

The maximum size and weight of aluminum die castings depend on the capabilities of the die casting equipment and the specific alloy being used. Generally, aluminum die castings can range from small, intricate components to larger parts weighing several kilograms.

Aluminum die castings exhibit excellent mechanical properties, including high strength, stiffness, and impact resistance. The specific mechanical properties depend on the alloy composition, heat treatment, and casting process parameters.

Yes, aluminum die castings can be customized to meet a wide range of design requirements, including complex geometries, special surface finishes, and functional features. Custom tooling and mold designs are often used to achieve unique part configurations.

Aluminum die casting is generally cost-effective for large production volumes due to its high-speed production capabilities, minimal material waste, and low labor costs per part. Compared to other manufacturing methods such as machining or forging, die casting often offers competitive pricing.

The quality control process for aluminum die castings involves rigorous inspections and testing at various stages of production, including material testing, dimensional inspections, and visual inspections. Advanced techniques such as X-ray inspection, pressure testing, and metallurgical analysis may also be employed to ensure the quality, reliability, and consistency of die castings.

Aluminum die casting offers several advantages, including high strength-to-weight ratio, excellent dimensional accuracy, and the ability to produce complex shapes with tight tolerances. It is also cost-effective for large production volumes and provides good surface finishes.

Aluminum die casting is one of the most cost-effective metal casting process. Though it takes more time to manufacture die-cast molds, a single mold can yield thousands of product units. At Echofast, we  specialize in aluminum die casting, and offer discounted rates for large quantity orders.

The most significant difference between die casting and sand casting is the material used for molding. Aluminum die castings employ molds crafted from aluminum alloy, whereas sand casting relies on molds made of sand.

Sand casting excels in managing intricate designs, while die casting prioritizes superior dimensional precision and efficiency. Additionally, sand casting yields thicker walls compared to die casting, which is adept at producing thinner walls. Consequently, sand casting may not be viable for smaller components.