Die casted aluminum
Die casting is an efficient process with great accuracy and where tool investments is relatively low. This is the main reason why die casting is used in so many products from electronics, cars and household.
Advantages of die-cast aluminum
Die casting is an automated process with high capacity, high quality, small tolerances and a fine surface. In addition, surplus material can be recycled back into the production.
Threads and areas high requirements for tolerances are machined after casting. The surface can be sandblasted, varnished, polished, chrome-plated etc.
Examples of die-cast aluminum components with different surfaces
Aluminum alloys
The most common aluminum quality we use is ADC12 (also known as A383) which is the most widely used material in die casting due to the combination of strength, durability, temperature resistance and good machining properties. Other alloys can also be used, but might give a slightly higher cost and require a higher MOQ.
Die-cast aluminum component with details by CNC machining
As a basis for tool production, we need a 3D model of the component (STEP format) as well as 2D drawing with all details. Before we can start production of the tool, we will have a technical evaluation to clarify that all details.
The steps in the production of tooling for die-cast aluminum
Time schedule for die casting
The production of tooling will normally take 4-5 weeks. We deliver a few samples for approval. Once these have been approved, production can start. Normal production time is 4 weeks.
Tool for die casting aluminum
Facts about die casting
During die casting, liquid aluminum is filled into a steel tool and kept under pressure until it solidifies. The tool normally has a fixed and a movable part, where the movable part has ejector pins to eject the finished part. The tool may have movable slides, cores and sections for making holes and other designs in the casting. The working pressure is between a few MPa to approx. 150 MPa.
Aluminum becomes liquid at 660 ° C and behaves like water at this temperature. Therefore, great accuracy is required of the tooling.
Aluminum parts directly from the die casting process. As the next step,
the inflow channels are removed and this material goes back to the raw material and is used again
Die casted aluminum after extra material has been removed
Recycling of metal, both from own production and from used products, reduces material costs, and is an environmental benefit compared to, for example, plastic. When recycling aluminum, only a fraction of the energy is needed compared to producing new material.
Aluminum weight is 2.7 kg / dm3, which is 1/3 of the weight of steel. Die-cast aluminum parts have great strength compared to its low weight.
PROCESSES
Extrusion - machining - casting - cold forming - turning - sheet metal work - welding
SURFACE TREATMENT
Sandblasting - brushed surface - anodizing - ROHS compliant passivation.
FINISHING
Screen printing - laser engraving - powder coating