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.
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Die Casting Parts are REACH and 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
| Aluminum Die Casting Alloy Metals: |
A360 Aluminum Alloy. |
|
A380 Aluminum Alloy. |
|
A383 Aluminum Alloy. |
|
A413 Aluminum 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 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 |
|
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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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