Aluminum die casting alloys are lightweight and have high dimensional stability for complex part geometries and thin walls. Aluminum has 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 metal is critical to the die casting industry. The aluminum die casting process maintains long-lasting strength at very high temperatures, requiring the use of cold room machines. The molten metal, still in an open insulated tank, is placed into a furnace where it is melted to the desired temperature. The open, insulated tank is separate from the die casting machine, and molten metal is drawn out of the tank each time a cast is cast, as these high temperatures can damage the normal pumping system.

The casting process uses steel molds and is typically capable of producing tens of thousands of castings in rapid succession. The mold must be divided into at least two parts to allow removal of the casting. The casting cycle begins with the two mold halves being clamped tightly together by the die casting press. Molten aluminum is injected into the mold cavity where it solidifies rapidly. These sections are firmly mounted in the machine and arranged so that one is stationary and the other is movable. The mold halves are pulled apart and the casting is ejected. Die casting molds can be simple or complex, with movable slides, cores or other parts, depending on the complexity of the casting. Most machines use a mechanism powered by hydraulic cylinders to achieve locking.

What are the advantages of aluminum die castings?
There are many reasons why aluminum is the most commonly cast non-ferrous metal in the world. As a lightweight metal, the most common reason for using aluminum die casting is that it can create very lightweight parts without sacrificing strength. Aluminum die castings also have more surface finish options and can withstand higher operating temperatures than other non-ferrous materials. Aluminum die castings are corrosion resistant, highly conductive, and have good stiffness and strength-to-weight ratios. The aluminum die-casting process is based on rapid production and can produce large numbers of die-cast parts very quickly and more cost-effectively than other casting processes. Aluminum die casting has become a favored choice for buyers worldwide. Features and benefits of aluminum die castings include:

lightweight and durable
good strength to weight ratio
preservative
excellent electrical conductivity
Fully recyclable and reusable in production