Aluminum Die Casting Companies: Choosing the Right Partner

As the transportation and construction industries struggle to deal with the pandemic economy, aluminum die casting companies are still in operation and meeting market demands for high-strength and lightweight castings. When choosing to work with an aluminum die casting company, suppliers need to ask in-depth questions about the equipment, process, and discuss expectations for the final product.

It’s a highly specialized field requiring consistency and repeatability. With the right equipment and an experienced foundry workers, you have an optimal set-up and the castings will deliver value to your project.

Use this guide when choosing a die casting partner:

• • What is aluminum die casting?
  • Aluminum die casting benefits
  • Die casting applications
  • Aluminum die casting choices
  • Aluminum die casting considerations

What Is Aluminum Die Casting?

Aluminum die casting is the process of shaping molten metals to a mold through high pressure. Die casting is possible with a variety of non-ferrous metals, but in the transportation industry, aluminum is the leading metal used because of its light weight and durability.

Aluminum Die Casting Benefits

Manufacturers have looked to this process to create more lightweight components. Aluminum’s durability and lightweight attributes make it an ideal fit for transportation and industrial applications.

Here’s why aluminum works so well for die casting projects for the transportation industry:

• • • Corrosion-resistant
    • Quick production process
    • Cost-effective
    • Environmentally friendly as it’s recyclable
    • Excellent strength-to-weight ratio
    • Good electrical conductivity

Die Casting Applications

• • • Original equipment manufacturers (OEM)
    • Ball bearings
    • Brackets in electric and stepper motors
    • Cylinder blocks
    • Electronic covers for gearboxes, motors, and more
    • Engine parts, including cylinder heads, blocks, and gas engine components
    • Lightweight components to boost fuel economy (and lower CO2 emissions)
    • Wheel parts and bearings
    • Suspension arms

Aluminum Die Casting Choices

One of the biggest challenges in die casting is determining which aluminum to use in your die cast. There are multiple options, each having its own advantages. Much of it comes down to the function of the part. Here are some of the most popular alloys:

• • • Aluminum Alloy A360
    • Aluminum Alloy A380
    • Aluminum Alloy 383
    • Aluminum Alloy 384

Consulting with an experienced casting foundry is recommended in making the right alloy choice. It’s instrumental to the design phase and the quality of the overall part. For example, A218 may be your aluminum of choice, but it’s more difficult to die cast. Each alloy will respond differently to machining and surface treatments and a reputable and experienced die casting company will be prepared to discuss these selection guidelines with you.

Aluminum Die Casting Considerations

Aluminum die casting has been in use for some time, but it’s still an evolving discipline. These considerations are important for all stakeholders to understand and discuss with your casting company.

Additional best practices to discuss prior to die cast production:

• • • Consistent quality
    • Testing
    • Aging treatments to reduce stress and stabilize the metal
    • Constant temperature protocols to ensure accuracy
    • Adding secondary processes, like heat treatments and fluorescent penetrant inspection (FPI)

Industry Demand

The price of aluminum is based on demand, and aluminum is a widely used alloy in the production of automotive parts, aerospace parts, railway equipment, electronics, and marine vessels. Demand could resurge post-pandemic and post-recession, but mining for aluminum (bauxite) may drop, impacting the price of aluminum. The casting foundry that you choose should have the latest information on aluminum pricing and  recent market knowledge.

Industry Advancements

As manufacturers retool their processes, lightweight aluminum will play a significant role. Make sure your die casting foundry understands the latest advancements in your industry and has experience with the CNC machining process.

New Technology

Advanced die casting technology make the process more efficient and cost-effective. These are must-haves for any manufacturer. Equipment innovations will also encourage greater quality, broader capacity for die cast providers, and the ability to manufacture a larger variety of sizes and shapes.

Die Casting Solutions

Finding the best solutions that meet your needs now and in the future is imperative. Learn more about how we can be your casting partner by exploring our capabilities.