Aluminium Die Casting Defects

2024-07-19 By Cherry 

Aluminum die casting is an efficient method for producing high-precision aluminum alloy parts, but various defects may occur in the 

actual production process.

These defects not only affect the quality and performance of the castings but also increase production costs.

This article will introduce the common defects in aluminum die casting and their solutions in detail, covering key content from 

astm b85 standards to a380 alloy chemical composition, to help readers fully understand and cope with the challenges in the aluminium 

casting process.

Classification of aluminum die casting defects

Aluminum die casting   defects can be roughly divided into the following categories:

1. Surface defects

2. Internal defects

3. Shape and size defects

4. Mechanical property defects

Surface defects

Surface defects refer to various irregularities or uneven phenomena on the surface of castings, including pores, inclusions, 

cracks, etc.

These defects affect the appearance and performance of castings.

Porosity: Porosity is a void formed during the cooling process of the casting due to the failure of gas in the aluminum liquid to 

be completely discharged.

Porosity not only affects the surface finish of the casting, but also reduces its mechanical properties.

Solution:

Control the melting temperature to avoid overheating.

Add an appropriate amount of exhaust duct during the casting process to ensure that the gas can be discharged smoothly.

Use high-quality aluminum alloy materials to reduce the gas content.

Inclusions: Inclusions refer to non-metallic impurities mixed in the aluminum liquid, which form irregular spots or particles on 

the surface of the casting.

Solution:

Use purification equipment and filters to remove impurities in the aluminum liquid.

Keep the casting equipment clean to prevent impurities from mixing into the aluminum liquid.

Standards and materials for aluminum die casting

1. ASTM B85 standard

astm b85 is an international standard for aluminum die casting alloys, which specifies the chemical composition, mechanical 

properties and casting process requirements of aluminum alloys. Following the astm b85 standard can ensure the quality and 

consistency of castings.

2. en ac 46000 Chemical composition

en ac 46000 chemical composition is a commonly used aluminum alloy material, and its chemical composition mainly includes aluminum, silicon, iron, 

copper, manganese, magnesium, and other elements. The specific chemical composition is as follows:

Aluminum (Al): Balance

Silicon (Si): 8.5-11.5%

Iron (Fe): ≤1.3%

Copper (Cu): ≤3.0%

Manganese (Mn): ≤0.3%

Magnesium (Mg): ≤0.1%

This alloy has excellent casting and mechanical properties and is widely used in automobiles, electronics, machinery and 

other fields.

3. Chemical composition of A380 alloy

A380 is another commonly used aluminum alloy with good casting and mechanical properties. Its chemical composition is as follows:

Aluminum (Al): Balance

Silicon (Si): 7.5-9.5%

Iron (Fe): ≤2.0%

Copper (Cu): 3.0-4.0%

Manganese (Mn): ≤0.5%

Magnesium (Mg): ≤0.1%

A380 aluminum mechanical properties are as below:

Aluminium casting process

The aluminum die-casting process includes the following main steps:

1. Mold design and manufacturing: Design the mold according to the shape and size of the casting, and use high-strength steel to make 

the mold.

2. Melting aluminum liquid: Heat the aluminum alloy material to a molten state and maintain the appropriate temperature and fluidity.

3. Injection into the mold: Inject the molten aluminum liquid into the mold under high pressure to ensure that the aluminum liquid can 

completely fill every detail of the mold.

4. Cooling and solidification: The aluminum liquid cools and solidifies in the mold to form a casting of the desired shape.

Removing the casting: Open the mold, take out the molded casting, and carry out subsequent processing.

Die casting advantages and disadvantages

Advantages of die casting

1. Efficient production: The die casting process can achieve large-scale and high-speed production, which is suitable for mass production.

2. High precision: Die castings have excellent dimensional accuracy and surface finish, reducing the need for subsequent processing.

3. High material utilization: The die casting process can maximize the use of materials and reduce waste and production costs.

Disadvantages of die casting

1. High mold cost: The manufacturing cost of die casting molds is relatively high, which is suitable for mass production but not for small 

batch manufacturing.

2. Material limitation: The die casting process is mainly suitable for low melting point metals, such as aluminum, zinc, magnesium, etc., 

and is not suitable for high melting point metals.

3. Defect control: Porosity, inclusions and other defects are prone to occur during the die casting process, and the process parameters need to 

be strictly controlled.

Comparison between magnesium die casting and aluminum die casting

Magnesium die casting and aluminum die casting are two common metal casting processes, which differ in material properties, application fields

and process characteristics.

Advantages of magnesium die casting

1. Lightweight: Magnesium alloy has a low density and is lighter than aluminum alloy, which is suitable for application scenarios with high 

weight reduction requirements.

2. Excellent mechanical properties: Magnesium alloy has good mechanical properties and impact resistance, and is suitable for parts with high 

strength requirements.

3. Good processability: Magnesium alloy is easy to process and form, and can realize the manufacture of complex structures and precision parts.

Disadvantages of magnesium die casting

1. High cost: The high production cost of magnesium alloy limits its wide application.

2. Strong corrosion resistance: Magnesium alloy has poor corrosion resistance and needs surface treatment to improve its corrosion resistance.

Surface finish of electroplated aluminum and investment casting surface finish

Electroplated aluminum and investment casting are two common surface treatment processes that can improve the surface finish and corrosion 

resistance of castings.

Electroplated aluminum

Electroplated aluminum is to electrochemically plate a layer of metal aluminum on the surface of aluminum castings to improve its corrosion 

resistance and aesthetics. 

The advantages of electroplated aluminum include:

1. Improve corrosion resistance: The electroplated layer can effectively protect aluminum castings and extend their service life.

2. Enhance surface finish: The electroplated layer can improve the surface finish of aluminum castings and improve their aesthetics.

Surface finish of investment casting

1. Investment casting is a precision casting process that can achieve high-precision and high-finish casting surfaces. The advantages of 

investment casting includes:

2. High precision: Investment casting can achieve the manufacture of complex shapes and precision parts, reducing the need for subsequent processing.

3. Excellent surface finish: Investment casting can achieve a high-finish casting surface, improving its aesthetics and performance.

ZAMAK 3 Chemical Composition

ZAMAK 3 chemical composition is a commonly used zinc alloy material with excellent casting properties and mechanical properties. Its chemical composition is as follows:

Zinc (Zn): Balance

Aluminum (Al): 3.9-4.3%

Copper (Cu): 0.25%

Magnesium (Mg): 0.03-0.06%

ZAMAK 3 and zamak 7 alloy is widely used in the manufacture of small precision parts, such as hardware, electronic product housings, etc.

Aluminum Casting Process

Aluminum casting processes include a variety of methods, such as sand casting, metal mold casting, die casting, investment casting, etc.

Different casting processes are suitable for different application scenarios and casting requirements.

Sand Casting

Sand casting is a traditional casting process that uses sand molds to form aluminum castings, suitable for large sizes and complex shapes.

For more info, you can refer to: https://www.youtube.com/shorts/JLX410QV_kw

Contact LK Egypt to learn more info about the die-casting machine

LKAGENT OFFICE DCM

Address: Industry Zone, South of Port Said Kebly, Egypt

https://www.zazdiecasting.com/

Phone/WhatsApp/Wechat: +86 13598704163

Mobile: +20 101 304 3317      +20 150 181 8310

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