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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.
The raw materials used in making the alloys for aluminum die casting parts are all recycled materials. It is less expensive to melt down aluminum wheels and aluminum cans and create aluminum die casting alloys, than it costs to mine the materials to make raw aluminum. Contact or Request Prices

Die Casting Parts are REACH and RoHS 3 Compliant RoHS 3 Compliant

Die Casting Parts use RECYCLED Materials and comply with the EU RoHS 3 standards. Die casting alloys have less than 0.1% of any of the REACH chemicals.
Registration: Chemical producers are required to register safety data for all chemicals produced.
Evaluation: Experts from member states and the European Agency evaluate safety data for higher volume chemicals and other chemicals of concern.
Authorization: Chemicals that are "substances of very high concern" (SVHC) are to be phased out and replaced with safer alternative chemicals.
Restriction: Chemicals may be completely banned or some uses of the chemicals can be restricted

Kinetic Die Casting Production Alloy List:

Kinetic Die Casting Comapny use the die casting alloys in this list for 90% of our production castings. Die casting metal alloys:
Aluminum A380 Die Casting Alloy.
Zinc-Aluminum ZA-27 Die Casting Alloy.
Zinc or Zamak #3 Die Casting Alloy.
Aluminum A360 Die Casting Alloy.
Aluminum A383 Die Casting Alloy.
Aluminum A413 Die Casting Alloy.
Aluminum K-Alloy Die Casting Alloy.


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
Tolerances:
  • Aluminum die cast parts ± .002"/in.
  • Add ± .001" to ±.015" across parting line depending on size.
    Size Range: Not normally over 2 feet square.
    Part Weights: .001 pounds to 10 pounds.
    Setup Cost: New tooling setup is free with free first article report.
    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 ALLOY MATERIALS

    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 REACH and the EU RoHS 3 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

    What surface treatments can I use for my die castings?

    A list of die casting surface treatments or surface coatings for die casting parts would include E-coat, powder coating, PVD, Hard anodize, Chem-Film or Alodine, Chromate, wet paint, zinc plate coating or galvanizing.

    PURPOSE ALUMINUM ZINC ZA
    Decorative
    finish
    Paint
    Polish/Epoxy
    Plate
    Powder coat
    Paint
    Plate
    Chromate
    Phosphate
    Paint
    Plate (ZA-8, ZA-12)
    Chromate
    Phosphate
    Environmental
    or galvanic
    corrosion barrier
    Paint
    Chromate
    Anodize
    Iridite
    Paint
    Chromate
    Anodize
    Iridite
    Paint
    Chromate
    Anodize
    Iridite
    Fill and seal
    surface and
    subsurface
    Impregnate
    Impregnate
    Impregnate
    Improve wear
    resistance
    Hard anodize
    Hard chrome plate
    Hard chrome plate
    (ZA-8, ZA-12)

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    North American Diecasters Association
    NADCA North American Die Casters Association
    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.


    Compare High pressure die casting to Other Manufacturing Processes

    Why Use Die Casting in aluminum:

    Diecasting machine injects aluminum into mold to make parts

    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.

    Glossary of Die Casting Terms

    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.


    Kinetic Parts
    KineticDC         		Kinetic Die Casting Company
    6918 Beck Avenue North Hollywood, California
    91605 United States of America
    800-524-8083 or 818-982-9200 or fax N/A

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