Processes / Products

Aluminum Die Casting

Die Casting is a process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Aluminum is lightweight, while possessing high dimensional stability for complex shapes and thin walls. Aluminum has good corrosion resistance and mechanical properties, high thermal and electrical conductivity, as well as strength at high temperatures. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes. Die Casting is an efficient, economical process that offers a broader range of shapes and components than any other manufacturing technique. Designers can gain a number of advantages and benefits by specifying die cast parts.

Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Die cast parts are important components of products ranging from simple handles to as complex as a connector housing.

Advantages include:

• High-speed production – Little or no machining is required and thousands of identical castings can be produced before additional tooling inserts are required.
• Dimensional accuracy and stability – Die Casting produces parts that are durable and dimensionally stable, while maintaining close tolerances.
• Strength and weight – Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
• Multiple finishing techniques – Die cast parts can be produced with smooth or textured surfaces, and they are easily finished with a minimum of surface preparation.
• Simplified Assembly – Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.

Casting Processes