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When it comes to making parts for an assembly or final product, manufacturers have to consider a wide variety of techniques and come up with the right fit for the job at hand. Fortunately, there are more methods available to us than ever before and aluminum high pressure die casting is one of them. This is a method that is widely used, but before you decide if it is the right choice for what you have in mind, let's take the time to get a closer look and find out more. We will be talking today about the process of die casting itself, how it works, why aluminum high pressure die casting can be a smart idea, the quality levels possible with this kind of die casting and the less positive side of the process that you need to know about before you decide whether or not it is the best choice for your needs. It's time to get started finding out more right now.
A Little Bit About Die Casting Itself
For those who may not know, die casting is a type of manufacturing process that involves a steel mold which is referred to as a die. A die is essentially two matching pieces of solid steel, or a similar metal in some cases, that has been sliced into two parts so that it fits together perfectly. The insides of those two pieces are then tooled out to form two cavities that will be pressed together prior to the process of die casting taking place. This way, those two halves seal their cavities together to create one solid cavity. The molten metal is then pushed into the cavity and allowed to cool. Once it has cooled, the halves of the die are then separated and a metal part is thereby produced. Generally, a high amount of pressure is needed to do this since even liquid metal is not easy to move and the substance needs to get into every crevice of the die's cavity. Also, keep in mind that different alloys other than those containing aluminum are sometimes used although today our focus is going to be on those alloys which feature aluminum.
What Makes Aluminum a Good Choice As a Die Casting Alloy?
There are several reasons that aluminum is chosen to be in the alloy for die casting. For one thing, it has a high degree of dimensional stability and this is important when a complex shape is desired. Not all metals can achieve this and for delicate pieces, aluminum high pressure die casting can often produce an amazing product that would otherwise not be possible. In addition, aluminum is lightweight and it does not corrode easily. Many different types of parts can benefit from this aspect of the metal itself, but remember, too, that it will bear high temperatures without weakening and can conduct electricity, as well. These are all strong points and they aid during manufacturing when speed is needed and costs have to be kept low while still producing accurate parts. All but 10 to 20 percent of the world's die cast alloys will contain at least some aluminum because it is such an easy metal to work with. It lasts quite a long time and also can be used for fairly large parts that may weigh quite a few pounds which is not the case with other metals that could be used instead. This versatility is a big part of aluminum's appeal.
High Quality vs Low Quality Aluminum High Pressure Die Casting
There are certainly variations in quality when it comes to aluminum high pressure die casting and you need to understand this right off the bat. In some instances, parts do not need to have a specific finish or they are not intended to be very detailed. This kind of low quality die casting is relatively simple, takes less time to do the tooling and can save money, but it is not going to be right for all types of projects. There will be other times when a part is quite complex and even when smaller runs of the part are possible due to the more complex process involved, the higher quality means better detail and a better finish which is crucial for the project. Everything comes down to choosing the right fit for the particular project and this is why finding the right manufacturer to handle any given project is a must. Once that provider is found, things should flow along more smoothly because overall, aluminum high pressure die casting is a process that is intended to be fast, inexpensive and easy once the initial dies have been created.
Drawbacks You Should Understand About Aluminum High Pressure Die Casting
The number one thing that stops some from choosing this kind of high pressure die casting is that it can be expensive. This is because the cost to produce the initial dies is simply not low in the majority of cases. The machinery needed to deliver the intense amounts of pressure needed is not cheap, either, and that will also contribute to the expense involved. Other casting processes will most likely be cheaper in a lot of instances, but they have a range of disadvantages of their own that you would be wise to consider as they relate to your specific project. Aluminum is a high fluidity metal and this is great for many things, but aluminum will not be the right choice for every project. This is why when determining whether or not aluminum high pressure die casting is going to be the right fit, it is very important to determine whether large volume production of said parts is likely to be profitable. If it is, this can certainly be a terrific process with a lot of benefits, but it is not always the case. Gas porosity, too, can be a setback that prevents welding. This is why parts that need to be welded must be of the highest possible quality level.