Advantages Aluminium Die Casting

The Advantages of Aluminium in Die Casting

At Lupton & Place, we are proud to be the UK’s premier provider of Aluminium Die Casting services. With decades of experience, our expert fabricators can provide the aluminium die casting that you need, and thanks to the advantages of aluminium and the die casting process, these castings are high-quality, adaptable and ideal for use in a wide variety of applications. If you aren’t sure whether aluminium die casting would be a good fit for you, you can ask one of the experts at Lupton & Place – they’ll be happy to provide any advice and information you need, and can help you find the perfect manufacturing solution to suit your needs.

What is Aluminium Die Casting?

Aluminium die casting is a manufacturing process which involves pouring or injecting molten aluminium into a set of specially made hardened steel moulds (or dies) and then removing or ejecting them when cool, resulting in an aluminium component which is the same every time, with a high degree of reliability and precision. The most expensive and time-consuming part of any aluminium die casting is preparing the mould – cutting it to shape, treating it and preparing it for use – and the actual process of pouring and ejecting the aluminium takes very little time by comparison. This, combined with the near-perfect replication of the component with each casting, makes aluminium die casting the ideal method for mass-producing aluminium components.

What Kinds of Aluminium Die Casting Are There?

Aluminium die casting usually comes in two forms, and which one you choose to use will depend on your requirements, as they each have advantages and disadvantages which make them ideal for certain sorts of use.

Aluminium Gravity Die Casting uses the natural force of gravity to fill the die. As it requires much simpler tools than aluminium pressure die casting, gravity die casting is cheaper and less time-consuming, and as the molten metal is poured vertically into the mould under normal pressure conditions, many of the problems which can occur during a high-pressure aluminium injection are avoided. Issues like the metal being introduced to the mould too quickly and folding over on itself, or trapping gas within the mould, are much less likely to occur under normal pressure, although gravity alone may not have the force required to push the molten aluminium into the thinnest spaces in the dies, making gravity aluminium die casting more ideal for larger, thicker components, or in smaller order volumes. Where the final component needs to be heat treated, gravity aluminium die casting is the way to go – and it can even be used alongside a sand core for very complex casting designs!

Aluminium Pressure Casting, by contrast, is a more technically intensive process which involves injecting the molten aluminium at high pressure into the hardened steel dies. Complex machinery is involved, so aluminium pressure casting tends to be more expensive, but as an additional point of contrast to gravity die casting, the injection process in aluminium pressure casting is automated, resulting in considerably faster production times and an extremely high degree of reliability in the fabricated components.

The speed and reliability of high pressure aluminium die casting, as well as the high dimensional accuracy of the pieces, is often seen as making up for the comparative lack of flexibility in the automated process. The speed and reliability of aluminium pressure casting make it the perfect solution for mass-producing very high volumes of identical components, particularly if those components are thin or require precise dimensions. The cost involved proportionately decreases as the production volume increases, as the expensive set-up is distributed across many castings – another reason why aluminium pressure casting is ideal for large volumes of components.

What are the Advantages of Aluminium Die Casting?

Aluminium die casting has a range of advantages as a production method, but it is also benefited by the advantages of aluminium as a metal and a die casting material. An exceptionally light metal, aluminium offers an exceptional strength-to-weight ratio and material hardness, making it ideal for lightweight, high-strength components like those found in the automotive and aerospace industries.

Aluminium also offers incredible corrosion resistance, and with high operational temperatures and high-quality thermal and electrical conductivity, aluminium die castings are a great choice for challenging environments and uses.

As a last advantage, aluminium die casting creates components which are fully recyclable. In many cases they can even be melted down and recast!

For more information or to enquire about a quote for aluminium die casting from Lupton & Place, you can get in touch at any time by using the contact form on this site, or by calling us on 01282 422361. The experts at our head office will be happy to help you find the ideal die casting solution to suit your needs!

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