Technical Information about Die Casting
Die Casting, A Description of the Die Casting Process -
Die casting is a manufacturing process in which molten metal is injected, under considerable pressure,
into a hardened steel die or also called die casting mold. Dies are often water-cooled. The die is then opened,
and the die casting parts are ejected (many times thousands of die casting parts each day, sometimes only a few hundred die casting parts).
Once the die casting tooling is paid for, die casting parts are a very inexpensive aluminum part manufacturing process.
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Technical Information about Die Casting Aluminum Alloys
Chemical Breakdown of Die Cast Aluminum Alloys
Compare Other Die Casting Materials to Aluminum
Compare Die Casting to Other Manufacturing Processes
| Aluminum Die Casting Alloy Metals: |
A360 Aluminum Alloy. |
|
A380 Aluminum Alloy. |
|
A383 Aluminum Alloy. |
|
A413 Aluminum Alloy. |
Size Range: Not normally over 2 feet square.
Part Weights: .001 pounds to 10 pounds.
Parts comply with the EU RoHS standards
Setup Cost: New tooling setup is free with free first article report.
Tolerances:
Aluminum die cast parts ± .002"/in.
Add ± .001" to ±.015" across parting line depending on size.
Surface Finish: 32-63RMS.
Minimum Draft Requirements: Aluminum 1° to 3°.
Normal Minimum Section Thickness:
Aluminum die cast parts: 0.060" small parts, 0.090" medium parts.
Ordering Quantities: Sometimes less than 100 parts, but usually 1,000 parts or more.
Normal Lead Time:
Tooling: Sometimes as little as 4 weeks or as much as 12 weeks.
Samples: Usually the week the die is available.
Production: Starts usually within two weeks (sometimes less) after approval.
Technical Information
about
Die Casting Aluminum Alloys
The following table will provide a general idea of the differences in Aluminum Die Cast alloys. Kinetic Die Casting will help you any technical information. A little information about Kinetic Die Casting Company can be found on our profile page.
ALUMINUM ALLOY CHARACTORISTICS | Aluminum die casting alloys
|
A360 |
A380 |
A383 |
A413 |
| Hardness |
75 |
80 |
75 |
80 |
| Elongation (% in.2 in.) |
2.5 |
3.5 |
3.5 |
2.5 |
| Shear Strength (ksi) |
28 |
28 |
- |
25 |
| Tensile Yield Strength (ksi) |
25 |
23 |
22 |
21 |
| Ultimate Tensile Strength (ksi) |
44 |
46 |
45 |
43 |
| Thermal Conductivity |
65 |
56 |
56 |
70 |
| Electrical Conductivity (% copper) |
30 |
27 |
23 |
31 |
| Density (weight) Lbs./ in.3 |
0.095 |
0.099 |
0.099 |
0.096 |
|
ALUMINUM ALLOY ADVANTAGES | Aluminum die casting alloys
|
A360 |
A380 |
A383 |
A413 |
|
(1= most desirable, 5= least desirable): |
|
|
|
|
| Pressure Tightness |
2 |
2 |
2 |
1 |
| Die Filling Capacity |
3 |
2 |
1 |
1 |
| Anti-Soldering to Die |
2 |
1 |
2 |
1 |
| Corrosion Resistance |
2 |
4 |
3 |
2 |
| Machining ease & quality |
3 |
3 |
2 |
4 |
| Strength at high temperatures |
1 |
3 |
2 |
3 |
| Material cost |
3 |
1 |
2 |
4 |
|
| Aluminum die casting alloys
|
A360 |
A380 |
A383 |
A413 |
| Silicon (Si) |
9.0-10.0 |
7.5-9.5 |
9.5-11.5 |
11.0-13.0 |
| Iron (Fe) |
2.0 |
2.0 |
1.3 |
2.0 |
| Copper (Cu) |
0.6 |
3.0-4.0 |
2.0-3.0 |
1.0 |
| Manganese (Mn) |
0.35 |
0.50 |
0.50 |
0.35 |
| Magnesium (Mg) |
0.4-0.6 |
0.10 |
0.10 |
0.10 |
| Nickle (Ni) |
0.50 |
0.50 |
0.30 |
0.50 |
| Zinc (Zn) |
0.50 |
3.0 |
3.0 |
0.50 |
Tin (Sn) |
0.15 |
0.35 |
0.15 |
0.15 |
Others |
0.25 |
0.50 |
0.50 |
0.25 |
Aluminum (Al) |
Balance |
Balance |
Balance |
Balance |
Aluminum Die Cast Parts comply with the EU RoHS standards
Other Die Casting Alloy Materials Comparison
| |
Aluminum |
Brass |
Magnesium |
Zinc |
| Tensile
strength, psi x 1000 |
47 |
55 |
34 |
41 |
| Yield
strength, psi x 100 (0.2 pct offset) |
23 |
30 |
23 |
? |
| Shear
strength, psi x 1000 |
28 |
37 |
20 |
31 |
| Fatigue
strength, psi x 1000 |
20 |
25 |
14 |
7 |
| Elongation,
pct in 2 in. |
3.50 |
15 |
3.0 |
10 |
| Hardness (Brinell) |
80 |
91 |
63 |
82 |
| Specific
gravity |
2.71 |
8.30 |
1.80 |
6.60 |
| Weight,
lb/cu. in. |
0.098 |
0.305 |
0.066 |
0.24 |
| Melting
point (liquid), °F |
1100 |
1670 |
1105 |
728 |
| Thermal
conductivity, CG5 |
0.23 |
0.21 |
0.16 |
0.27 |
| Thermal
expansion, in./in./°F x 106 |
12.1 |
12.0 |
15.0 |
15.2 |
Electrical
conductivity,
pct of copper standard |
27 |
20 |
10 |
27 |
| Modulus of
elasticity, psi x 106 |
10.3 |
15 |
6.5 |
? |
| Impact
strength (Charpy), ft/lb |
3.0 |
40 |
2.0 |
43.0 |
|
Die Casting Process
|
Kinetic Die Casting Company uses the die casting process to make aluminum die castings and zinc die casting parts. The die casting process, simplified, is described as follows: Our customer provides us tooling (https://www.kineticdiecasting.com/tooling.html), a die, a mold or inserts that we use to make their parts. We can also produce the tooling for our [...]
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Plastic Strength or Castings
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Die Casting Aluminum Process
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The die casting aluminum process involves the injection of molten aluminum into molds or casts by using very high pressure. Four essential steps are undertaken in aluminum die casting, first of which is spraying the mold with lubricant and closing the die casting machine. The lubricant is used not only to facilitate casting removal but [...]
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Kinetic Aluminum Handles
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Diecasting Airplane Parts
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Die Castings used for many Aircraft Parts. Demand for diecast airplane parts is increasing in the aircraft industry. Airplanes need lightweight materials for mobility. Moreover, planes require durability and resistance to several stresses while flying. Among metals, aluminum is used to serve as frames or skeletons of the aircraft. In the aircraft industry, the strength [...]
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Recycling Aluminum Die Castings
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Casting Process
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Casting is the process of molding metals into different shapes and sizes to create metal parts. One of the oldest casting methods is gravity casting. Gravity casting uses gravity to make sure that all the parts of the mold is filled by the melted metal like aluminum or zinc. A gating system is produced to [...]
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Zinc Price Spike
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Zinc Price Spike Sparks Flurry of Miner Listings A doubling in zinc prices since late 2015 and strong outlook for the commodity has fueled a flurry of zinc miner listings on the Toronto Stock Exchange as companies cash in on investor demand for producers of the metal. Brazil-based Nexa Resources, a top five global zinc [...]
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Zinc Miniature Parts From Kinetic Die Casting Company
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Die Casting, Zinc Miniature parts. Aluminum die cast Parts created by Kinetic Die Casting Company could be stronger than steel. Kinetic Die Casting is a die cast part manufacturer of better quality Aluminum die cast parts. Kinetic Die Casting has Low Quantity Die casting Production or High Quantity Die casting Part Production. High pressure Die [...]
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Fun Facts About Aluminum
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Aluminum (Al) is the most abundant mineral on Earth after oxygen and silicon and is the most abundant metal found naturally on Earth. It is present in 270 minerals. Aluminum is a silver, soft metal with an atomic number of thirteen and thirteen protons in the nucleus. It constitutes about eight percent of the Earth’s [...]
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We are a Corporate Member of NADCA (North American Die Casters Association).
NADCA helps manufacturers (OEM's and Die Casters) with information concerning die casting of all types and materials.
NADCA also publishes specifications for die cast parts.
North American Diecasters Association
Compare High pressure die casting to Other Manufacturing Processes
Forgings
Compared with forgings, die casting can be more complex in shape and
have shapes not forgeable, can have thinner sections, be held to closer
dimensions, and have coring not feasible in forging.
Plastic Injection moldings
Compared with plastic injection moldings, die casting are stronger,
stiffer, more stable dimensionally, more heat resistant, and are far
superior to plastics on a properties/coat basis. They help prevent
radio frequency and electromagnetic emissions. For chrome plating, die
castings are much superior to plastics. Die castings have a high degree
permanence under load compared to plastics, are completely resistant to
ultra-violet rays, weathering, and stress-cracking in the presence of
various reagents. Manufacturing cycles for producing die castings
are much faster than for injection moldings.
Extrusions
Compared to extrusions, die casting can be produced faster and more
net shape. Features and depressions on the sides, tops and bottoms can
be created in one operation. There is less waste using die casting than
extrusion. Holes can be cast in place to save additional machining
cost.
Stampings
Compared with stampings, one die casting can often replace several
parts. Die casting frequently require fewer assembly operations, can be
held within closer dimensional limits, can have almost any desired
variation in section thickness, involve less waste in scrap, and are
producible in more complex shapes. Die castings can be made in many
shapes not producible in stamped form.
Screw Machine Parts
Compared with screw machine products, die castings are produced more
rapidly, involve much less waste in scrap, can be made into shapes that are difficult or impossible to produce from bar or tubular stock, and may require fewer operations.
Sand castings
Compared with sand castings, die castings require much less
machining, can be made with thinner walls, can have all or nearly all holes cored to size, can be held within much closer dimensional limits, and are produced more rapidly in dies which make thousands of die castings without replacement. Die castings do not require new cores for each casting, are easily provided with inserts die cast in place, have smoother surfaces and involve much less labor cost per casting.
Permanent mold castings
Compared with permanent mold castings, die castings can be made to
closer dimensional limits and with thinner sections and holes can be
cored to near net shape. Die castings are produced at higher rates with
less manual labor, have smoother surfaces, and usually cost less per die casting.
Aluminum Die Cast Parts - End result of our efforts.
Die Casting Processes
Brass Parts Die Casting.
Tooling Die Casting.
Die Casting Draft Angle.
Alloys for Die Casting.
Aluminum Die Casting Company.
Zinc Parts Die Casting.
Magnesium Die Casting Company.
Porosity in Die Castings.
Sand Castings.
Technical Die Casting Terms.
Die Castings Compared to Steel.
Die Castings Compared to Plastic.
Capabilities of Die Casting.
Why use Diecasting.
What is Die Casting.
American Die Casting Company .
Manufacturing Die Castings .
Custom Metal Parts.
Diecast Quality Production.
Die Casting Aluminum.
Diecasting Company.
Kinetic Die Casting Company.
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