Aluminum Die Casting
Aluminum alloys have proved ideal for wide range of products because of the unique combination of qualities they posess; light weight, good corrosion resistance, high tensile strength, high dimensional stability, high thermal and electrical conductivity. Alloy 380, which has been selected as the standard Prima aluminum base die casting alloy, has been found to be the best adapted to meet general needs.
The advantage of die casting is that when appropriately designed, the casting can often be incorporated in the final component with little or no machining or subsequent finishing. Furthermore, quite large aluminum castings can be produced with very thin wall thickness to a high degree of flatness and can include, for example, cast-on bosses for assembling.
Die castings have replaced components which were formerly made from other manufacturing techniques. Compared with plastic injection molding, die castings are stronger, stiffer, more dimensionally stable, more thermally resistant and are far more superior to plastics on a properties/cost basis.
Compared with sand castings, die castings require much less machining; can be made with thinner walls; can have holes cored to size; can be held within much closer dimensional limits; are produced more rapidly in dies which make thousands of die castings without replacement; 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.
On the average, compared with permanent mold castings, die castings can be made to closer dimensional limits, with thinner sections and produced at higher rates with less manual labor.
Compared with forgings, die castings can be more complex in shape and have shapes that are not forgible; can have thinner sections; be held to closer dimensions and have coring not feasible in forgings.
ln relation to stampings, one die casting can often replace several parts. Die castings frequently require fewer assembly operations, can be held with closer dimensional limits, can have almost any desired variation in section thickness, involve less waste in scrap and are producible in the same forms as stampings.
Compared with screw machine products, die castings are often produced more rapidly, through the use of multiple cavities, involve much Iess waste in scrap, can be made in shapes difficult or impossible to produce from bar or tubular stock and require fewer operations.