Understanding Some Crucial Aspects Associated with Aluminum Die Casting

Aluminium die casting is a metal-forming process through which a large number of extremely complex alumininum parts are created. In this process, the ingots of aluminium undergo heat treatment under very high temperatures till the time they come into the complete molten state. The molten material is then injected into the steel die cavity which is also known as a mold. The die or mold is made up of 2 halves. When the liquid material gets solidified, both the halves are separated to bring out the cast aluminum part.
The resulting product is formed very precisely having an ultra-smooth surface that hardly calls for any further machining process. As most often the molds or dies are made of steel, aluminium die casting manufacturers in India can make use of the same mold many times until it completely deteriorates. This is the reason aluminum die casting is considered to be an ideal process to produce aluminum parts in high volume.

The advantages of aluminium die casting at a glance

Aluminium die casting offers a large number of advantages when compared to other metal-forming processes. One of the most prominent ones among them is its ability to create parts of the most complex and intriguing shapes and sizes that even extrusion and machining cannot create. Some of the finest examples of such shapes, comprehensively used in the automotive industry, include the following:

● Compressor Housings/Compressor Cover
● Timing Cases and Timing case cover
● Rear Sprocket
● Air Intake Pipes / Manifolds
● Fuel Dispenser Meter
● Transmissions and engine blocks, ETC.

No other process can consistently achieve the tight tolerances and complexity that these intriguing parts call for. Some additional advantages of aluminum die casting include the following:

● The ability to have textured or smooth surfaces
● The capacity to accommodate both large and small parts
● Lightweight end-product with unmatched dimensional stability
● The ability to cast thin walls and complex shapes
● Corrosion resistance and excellent mechanical properties
● High thermal and electrical conductivity
● High strength-to-weight ratio
● Environment- friendly with 100% recyclability
● Good tool life with overall excellent value
● Cost-effective. 

Some top considerations during part design

A couple of considerations must be taken into notice while planning the part to be cast. Firstly, the die should be designed to isolate and permit the hardened aluminum part to emerge. The line that marks where the two parts of the die fall to pieces is alluded to as a splitting line, and you need to consider it in the beginning phases of the mold designing. One more significant thought is the area of infusion points. The mold can be planned with a few injection points in situations when the liquid metal would somehow harden before arriving at the crevice in the mold.

This can likewise help to assume that cavities are included in the plan. You can also encircle them with aluminum and still have the parts behaving in a particular manner when the mold is separated. You should likewise think about the thickness of the part's walls. There are generally no rules for a base wall thickness, because of the latest innovations and improvements in technology. However, it is preferred to have walls with reliable thickness.

Options for machining and finishing

The parts created using aluminium die casting methodology often don’t call for any heavy machining and finishing exercise, still, there are a large number of methodologies available for finishing. Die casting offers unmatched surface finishes as per the casting standards but the end result might still have some imperfections, particularly in the areas wherein the die halves meet. To treat any imperfection or rough surface, the following methodologies can be adopted:

● Sanding
● Sandblasting, or
● Orbital sanding.

For improvement in fatigue resistance, shot peening – the cold working process - is adopted on the cast aluminium parts. As an alternative, a protective or decorative coating (powder coating) is also applied to meet the finishing needs of the cast parts. Some other types of modifications are also available to finish the parts after casting. And, drill tapping is one of them.

A look at the design engineering in terms of India’s leading aluminium casting manufacturers:

When it comes to the capabilities of the aluminium die casting manufacturers in India, things are now quite different and advanced like never before. Indian manufacturers are equipped with the latest infrastructure and seasoned professionals who can take on casting jobs of any complexity and intrigues. Some of the highlights from the design engineering area include the following:

● The latest software and manpower having a penchant for technology
● Proven capabilities in 3D Modelling, Rapid Prototyping, Soft Tooling, Permanent Tooling, and Reverse Engineering
● The ability to work towards optimizing the existing solutions and developing new ones
● The ability to execute product design validation for VE projects making use of solid modeling as well as rapid prototyping
● World-class simulation tools for refining mold design for high quality, durability, reliability, and minimum maintenance
● Design and Simulation software such as Creo – 5 (Pro/e), Magma, and CADIAN.

According to a recently released report by Transparency Market Research, the Asia Pacific region has more than half the share in the total production of the aluminum castings. It is also anticipated that the said region will pull in a CAGR of 5.3% by the end of the year 2025. Indian aluminium casting manufacturers have also taken the global call concerning the lightweight and premium quality castings to be used across industries, and each year they are proving their mettle within the industry while strengthening their stature.

Concluding Remarks

Caparo is one of the leading aluminium die casting manufacturers in India. The company has set up a world-class Aluminium foundry to manufacture intricate Aluminium castings through High Pressure Die Casting and Gravity Die Casting processes. It is backed by a dedicated workforce of 850 employees who have in-depth metallurgical know-how, and unmatched capabilities in design and engineering. Caparo Aluminium Casting division has installed STRIKO to make bulk tower melting and holding furnaces with a capacity of 1.5T per hour. Some other facilities include Dosing Furnace, Shot Monitoring and control, Trimming cells, Shot blasting facility, 2 Axis WOLLIN Sprayer, and 6 Axis ABB Robot.