Aluminum Die casting parts

Aluminium Die casting is a process that helps in the manufacturing of smooth or textured surface and dimensionally stable metal parts. Die casting create parts from a variety of non-ferrous and durable metals e.g. lead, aluminum, magnesium, zinc, tin, copper and other composite materials. These parts are largely used in mounting main and ancillary machines in the different industries including telecommunication, electric, automotive, hydraulic, lighting industries.

Various finishes are employed for enhancing the appearance based on the surface texture if needed. These finishes include shot blasting, orbital sanding, powder coating, etc. Here are some examples  of die casting parts:

Aluminium die casting
Aluminium die casting

Pinless tag clip

A pinless tag clip is a die casting part that is used in the shopping malls to safe clothes from being theft. It is a zinc die casting part which is very lightweight i.e. only 0.53 ounce.

Power conditioning module chassis

This die casting part is made of aluminum. Its weight is 2.3 lbs and the size is 30*30 cm. It is used in electronic machines as a replacement for machined components. It dies quickly only in 8 weeks and also cost-effectively.

Steering knuckles

It is a die casting part that connects the wheel with the steering components. Ultimate tensile strength of steering knock is greater than 2X which is a requirement of customers. Further, it is very strong and unbreakable in lower control arm tests. Die-cast Steering knuckles has 10% less weight and 5% cheap as compared to previous knuckles. On the basis of all these facts, it can be said that it has beaten all previous knuckles.

Thrust rods

The thrust rod is building blocks of BMW X5. This rod is a replacement of three stamped steel parts. In this way, the weight of die-cast thrust rods is 50% less compared to the previous ones.

Engine base bracket

The engine base bracket is a part of Honda. It has consolidated 16 parts into a single part and thereby removed the cost of assembling. The die-cast engine base bracket has reduced the weight by 44% in comparison with the steel fabrication. It is strong and ductile enough to meet the standards of the customers.

die casting parts
die casting parts

Engine subframe

Another example of the die casting parts is the engine subframe which is a part of the vehicle. It has a separate structure in the vehicle because it aims to save the passengers from the vibration and harness of the engine. It has consolidated 48 parts into 16 and in this way caused a reduction in weight and cost.

Shock tower

Shock tower is another application of automotive die casting. It is a part of BMW X5 and prepared by a high vacuum die casting. It is a replacement of 5 parts of the steel assembly. As a result, 40% of the weight is reduced.


Die casting parts are produced after melting the metal and then reshaping it. These parts are prepared in smooth as well as complex shapes and in any size depending on the manufacturer’s needs. They have many applications in various industries because they reduce the weight and cost by replacing many parts with single or few parts.

Common materials used in Die casting

Most utmost die castings are produce from non-ferrous metals such as:

  • Zinc Alloy die casting – zinc-based alloys are the easiest to die cast is high and impact strength is excellent, making these alloys suitable for a wide range of products.
  • Copper Alloy – copper based alloys are generally known as brass or bronze. They present the most powerfull mechanical properties of any of the normally die cast metals. Brasses have high strength and toughness, good wear resistance, and excellent corrosion resistance.
  • Aluminum Alloy – aluminum die casting alloys are lightweight, offer good corrosion resistance, ease of casting, good mechanical properties and dimensional stability.
  • Magnesium alloy – magnesium alloys are noted for low weight, high strength to weight ratio, exceptional damping capacity, and ease of machining. Castings temperatures are about the same as aluminum, and both hot chamber and cool chamber machines used to produce castings.
Advantages Disadvantages  
We get closer dimensional accuracyLittle bit more Expensive
Suitable for mass production Preparation of die takes lots of labor and time
Good surface finish Only small and medium size castings can be made
Less space is required as compared to the conventional casting Not suitable for small – scale casting
Operation time is less Suitable only for non – ferrous casting such as aluminum
Faster rate of production —————————————–
Semi – skilled workers can also do the job ——————————————
Less defects occur ——————————————
Smooth surface finish ——————————————

Aluminum product demand increase

China continues to be the primary driver of growth:

  • The people’s republic of china has long since become the world’s largest producer of aluminum, but even demand is growing there faster than anywhere else. China die casting continuous to be the primary driver of growth in the aluminum industry, and e-mobility is a major factor.
  • Global demand for primary and recycled aluminum is being fueled by the trend towards lightweight construction in the automotive industry. The consumption of aluminum is growing in the becoming aerospace industry, while the upturn in the construction industry in continental Europe is also stimulating demand. In addition, demand in the mechanical engineering and packaging markets continuous to increase.
  • The global alu die casting market size was estimated at USD 47.1 billion in 2018. It is anticipated to witness a CAGR of 9.1% from 2019 to 2025. Upswing in the use of aluminum is automobile manufacturing and heightened demand from the building and construction sector in Asia pacific has boosted the growth of the market.  

Summary of Die Casting;

Raw materials ingots

  • what are ingots
  • how to identify metal ingots
  • common materials used in die castings

Different die casting process

  • low pressure die casting
  • vacuum die casting
  • squeeze die casting
  • semi-solid die casting

Die casting step by step process

  • clamping
  • injection
  • cooling
  • trimming

Die casting defects

  • porosity
  • short shot
  • cold shut
  • hot tear
  • excessive flash

Aluminum die casting process

  • step by step process
  • aluminum production and demand
  • increase trend in casting

zinc die casting

GC Die Casting opened its doors as a supplier of zinc die casting in a 6,700 square foot building in September of 1967. The company started with four employees and with equipment that was state-of-the-art for the time. It was the company’s co-founder, the late R.B. “Bob” Grisbrook, focusing on prevention of defects rather than detection of rejects, who first set the standard for uncompromising excellence in every facet of the business to which the company adheres to this day.

We have recently undergone a change in ownership, and under this new leadership, the company has re-affirmed its three-decades-long commitment to excellence, and has taken that commitment to the next level, with a sharp focus on the leading-edge technologies, work processes, and skilled employees it takes to fulfill the expanding needs and high expectations of our customers.

Currently our markets served are primarily Electric Motor Products, Commercial/Industrial Equipment, Heavy Truck, Consumer/Lawn &Garden, Second Tier Auto/Aftermarket, and Telecommunications sectors

We recognize that all of our customers are in business – that they have business standards and business obligations to fulfill, commitments to their own customers to meet, and that those standards, obligations, and commitments are more demanding every day. Their competition is intense, and the expectations of their customers are high. They depend on their suppliers – suppliers like GC Die Casting, LLC – to support them in reaching their business goals by supplying them with products and services that are of the highest possible quality, and that are produced and delivered when they are needed.

That’s why everything we do – from the deployment of state-of-the-art technology to the employment of the very best people – is focused on order responsiveness and scheduling flexibility — making sure our customers get what they want and need, when they want it.

We operate three shifts, 24 hours a day, and with the implementation of a 4th and 5th shift concept, we have the capability of 7 days a week, 24 hours a day.

Permanent Mold Castings

Permanent mold (gravity die casting), like die casting, is suited to high-volume production. Permanent mold castings typically are larger than die castings. Maximum weight of permanent mold castings usually is about 10 kg, but much larger castings sometimes are made when costs of tooling and casting equipment are justified by the quality required for the casting.
Permanent mold castings are gravity-fed and pouring rate is relatively low, but the metal mold produces rapid solidification. Permanent mold castings exhibit excellent mechanical properties. Castings are generally sound, provided that the alloys used exhibit good fluidity and resistance to hot tearing.
Mechanical properties of permanent mold castings can be further improved by heat treatment. If maximum properties are required, the heat treatment consists of a solution treatment at high temperature followed by a quench and then natural or artificial aging. For small castings in which the cooling rate in the mold is very rapid or for less critical parts, the solution treatment and quench may be eliminated and the fast cooling in the mold relied on to retain in solution the compounds that will produce age hardening.

For hot chamber process the pressure chamber is connected to the die cavity is immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open (unpressurized) position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures. Such as Zinc Die castings, Copper Die castings we offer.

Some common aluminium permanent mold casting alloys, and typical products cast from them, are presented below.
* Alloy 366.0 – Automotive pistons
* Alloys 355.0, C355.0, A357.0 – Timing gears, impellers, compressors, and aircraft and missile components requiring high strength
* Alloys 356.0, A356.0 – Machine tool parts, aircraft wheels, pump parts, marine hardware, valve bodies, also can be heat-treated as T6, T651.
* Other aluminium alloys commonly used for permanent mold castings include 296.0, 319.0, and 333.0.
* Some Zinc Die casting, and copper alloy castings

Radiator housing

Radiator housing and Radiator bottom process

Drawing process (grinding)

Drawing process is to use a most bottom process. Drawing use some surface roughness and hardness has certain tools, common such as abrasive paper, file, etc, to deal with the object surface unidirectional, repeated or rotating friction, with the aid of the tool rough surface friction of scissors cutting effect to remove processing surface bulge objects; Of course, rubdown bulge content at the same time also on the original flat surface cause scratches. So should adopt from coarse to fine gradual process, and gradually reduce processing surface rough degree.Aluminum die casting

Drawing process features: a parallel grinding crack

Disk milling process (cutting)

Disk milling process is to point to will radiator bottom fixed after the high speed rotating tool cutting radiator surface, tool always in the same plane internal rotation, so cut out of the bottom very flat. And the same drawing technology, dish milling process of the tools being used more fine, cutting the bottom level of the higher level. Disk milling process of manufacturing cost is higher, but relative drawing only need two or three processes, more efficient, and the effect is ideal.

Disk milling process features: of arc grinding crack

CNC machine tool

For the Radiator housing or pther type of aluminum die casting parts, When we got die casting parts by high pressure die casting process. CNC machine tool applied to radiator of the bottom level processing mainly USES the technology is still milling. But with the traditional dish milling is different, CNC milling machine tool can through the single chip microcomputer accurate control and radiator of the relative distance between. Cutter contact fin base, both horizontal direction relative motion, then to the traditional dish milling cutter in the void left untreated cutting part, and to achieve complete plane effect, no any subsequent treatment can obtain mirror the general effect, roughness can be less than 0.001 mm.aluminium die casting

Other processes

For aluminium die casting, magnesiumd die casting, and zinc die casting parts. In addition to the above several outside, still have other radiator bottom processing technology, such as polishing, alodizing, powder coating, painting, however, relatively speaking, polishing processing are more beautiful considerations of radiator, radiator bottom flatness without too much improved, and the treatment cost is higher.

As we’ve mentioned, radiator bottom no matter how to deal with this kind of mechanical process could not make totally standard flat surface, the CPU and radiator between ravine or void is always inevitable. In these the air gap on the radiator of the conduction ability has a lot of influence, well known, air thermal resistance is very high, so must with other material to reduce the thermal resistance, or radiator of conduction performance will sell at a discount greatly, even can’t play a role. This is the origin of the heat conduction medium. Its role is to fill heat source such as CPU and the radiator greatly small gap, increases the heat sources and heat radiator contact area.

Die Casting Manufacturer

Die Casting Manufacturer for Aluminium, Zinc, Magnesium

The die casting is manufacturing process of casting accurately dimensioned, sharply defined, smooth or textured surface of metal parts, it is used to provide a beautiful finish to the different types of metal parts. Most die castings are made from non-ferrous metals, especially zinc, aluminum, magnesium, lead, pewter and tin-based alloys, depending upon the type of material being cast, a hot or cold chamber machine is used there are various type of die casting is done according to user’s requirements and the metal parts are designed in a well stylish way with a smooth finish.

The different types of casting include aluminum die casting, zinc die casting, magnesium die casting and so on, all of those type of die casting we called high pressure die casting, means use high pressure to inject the lquid material into the mold and getting cold and get the part which is according to our diesgn.

Aluminum die casting

The type of casting used to cast lightweight metal. In aluminum die casting, different types of aluminum is sued, and it is provided more protection to the metals to be casted with aluminum, it provides high dimensional stability for complex shapes and thin walls. It has good corrosion resistance. Include better mechanical properties. It has high thermal and electrical conductivity. And it can retain strength at high temperature.

Magnesium die casting.

Magnesium die casting is easiest metal to machine. It has the reputation for flammability. And its melting point is 600 degree centigrade. It uses powder coating, wet painting, hard anodizing and same plating materials for finishing.

It is the lightest alloy commonly used for die casting, it can be considered as the excellent strength weigh metal cater. But has a low corrosion resistance, which makes it less efficient

Zinc die casting

It is an ideal metal for casting. It is used to cast complex shapes easily, used in the creation of very thin walls. That are strong nonetheless. It can provide and attractive finish to your metal products at a low cost. It has outstanding corrosion resistance and increases the life of metal. It has the highest ductility. Provides benefits like high impact strength.

Can be easily plated, promises long mold life. Economical for small die parts.

Why we need die casting parts?

When we want to provide a better look to our metal parts then die casting is a process that can do this for us. For improving the quality and smoothly of metal machine parts we require the die casting

Advantages of die casting

These are the reasons that tell us that hoe much die casting is useful for us.

Provide excellent dimension accuracy faster production rates smooth cat surface, thinner walls can be cast.

Reduce of eliminate secondary machine operations. The casting of low fluidity metal can also be done easily

Aluminium Die Casting

Aluminium Die Casting

Casting of metals under pressure is a method of manufacturing castings from alloys, in which the alloy acquires the shape of a casting, quickly filling the mold under high pressure. This method is used for alloys of non-ferrous metals (based on zinc, aluminum, copper, magnesium, tin-lead alloy) because of their low melting point, and for some steels. The resulting products can be from tens of grams to tens of kilograms. we called this process as high pressure die casting processAluminium die casting

The main advantages of aluminium die casting under pressure are high productivity, minimal need for machining the product, and the fact that the blanks obtained in this way have a high surface quality.

Die-casting of aluminum under pressure is widely used for medium-series, large-scale or mass production of castings. The method of casting aluminum under pressure is widely used in the field of automobile and aircraft building, electrical engineering, instrument making, etc.

The main advantages of the pressure die casting method

  1. Productivity and economy.

The classical casting of aluminum alloys under pressure is still the most productive and the most economical. Therefore, aluminum in the form of castings under pressure still has the largest share among processed metals.

  1. Aluminum remains promising.

Industry, especially automotive, requires more and more light parts. Due to this and the above reasons, aluminum remains an indispensable material. The raw materials, bauxites, are available in large quantities. This gives us confidence that we will be able to innovate for a long time and work with aluminum for the future.

  1. Aluminum is relatively easy to melt.
  1. Metal is recycled – an important advantage in terms of environmental protection.

Another known casting method is zinc die casting. Technically pure zinc has satisfactory mechanical Zinc Die Castingproperties, it is well suited for rolling,
pressing, drawing and stamping in the cold state and in the temperature range 130 -170 degree. Zinc has a high density in the solid and liquid state, low melting and boiling temperature, linear shrinkage. They produce several brands of zinc, which differ in the quantity of impurities.
The main applications of zinc die-casting under pressure are the production of door fittings, carburetor cases, pumps, decorative elements, as well as the font-making industry. The parts made of zinc have a high density and well repeat the relief of the mold, therefore it is possible to make castings from them with already printed pattern and very small details.Magnesium die casting

Magnesium Die casting under pressure. The guaranteed availability and the combination of the positive properties of high purity magnesium alloys make the lightest metal structural material attractive for use in many industries, for example:

  • Lightweight parts for the automotive industry.
  • Cases for office machines, laptops, mobile phones and speakers.
  • Machines for domestic work, etc.

Properties and advantages of the method.

  • Due to very good fluidity, it is possible to produce even finer-walled or more complex parts than with aluminum die casting.
  • New applications in the electrical industry due to good thermal conductivity, as well as electromagnetic shielding of the metal.
  • Compared with plastics, greater strength and better thermal conductivity are achieved.
  • Magnesium reserves are practically inexhaustible.
  • Negotiable material is processed secondarily.
  • High-purity magnesium alloys are less susceptible to corrosion.
  • Good sound insulation properties from noise.
  • Weight reduction of approximately 30% compared to aluminum.

Die casting  is one of the most advanced methods of mass production of castings.

Along with such advantages, injection molding has a number of disadvantages.

1) High cost of basic equipment and molds;

2) Formation of porosity and shells in massive sections of castings, in connection with which the strength and tightness are reduced, thermal treatment of castings, is excluded;brass die casting

3) It is possible to fill only aluminum, magnesium, zinc and copper alloys ( brass die casting ), but not all fusible alloys, even aluminum, can be used for injection molding.

The economic feasibility of casting in one way or another, except for the technological design of the construction of the part, is determined by the laboriousness of manufacture and the technological possibility of making castings. The high cost of tooling equipment leads to the fact that the manufacture of castings by injection molding is economically feasible when ordering more than 20,000 pieces. With smaller orders advisable other methods.