Fabrication of Aluminium

2024-09-24 by Cherry

Introduction

Aluminum is widely used in industrial manufacturing due 

to its excellent physical and chemical properties. 

Especially in the use of die-casting machines, the 

lightweight, high strength, and good forming characteristics

of aluminum make it an ideal choice. This article will explore

the application of aluminum manufacturing in die-casting

machines in depth, analyze its advantages, process flow, 

common application areas and future development trends.

1. Characteristics and advantages of aluminum

Aluminum is a low-density, high-strength metal with good 

corrosion resistance and thermal conductivity. The following

are several advantages of aluminum in die-casting machines:

1.1 Lightweight

Low density: The density of aluminum is about 2.7g/cm³, which

is only about one-third of steel. This makes aluminum 

products lighter in weight at the same volume, easy to 

transport and install, and reduces energy consumption. It allows

aluminum castings to maintain sufficient strength while 

reducing the product's overall weight. This is particularly

important for industries such as aerospace and automobiles,

which can improve fuel efficiency.

Good electrical and thermal conductivity: The electrical 

conductivity of aluminum is second only to silver, copper, 

and gold, and it is widely used in electrical and electronic

fields. At the same time, aluminum has very good thermal 

conductivity and is often used to manufacture heat exchange 

equipment such as radiators.

1.2 Excellent fluidity

The low viscosity of aluminum gives it excellent fluidity 

in a liquid state, which is essential for the die-casting

process. It can effectively fill the mold and ensure that 

complex-shaped castings are defect-free.

1.3 Corrosion resistance

Aluminum can quickly form an oxide film in the air, which

can effectively prevent further oxidation and extend the 

service life of the product. This is especially important

for many application scenarios that require environmental 

corrosion resistance.

Strong machinability: Aluminum has good plasticity and

machinability, and can be made into products of different 

shapes and sizes through various processing methods. For 

example, aluminum liquid can be quickly formed into complex

parts through a die-casting machine.

2. Working principle of die-casting machine

A die-casting machine is a device that injects molten metal

into a mold under high pressure to make castings. The 

die-casting process is generally divided into two types: 

cold chamber and hot chamber.

2.1 Cold chamber die-casting machine

Cold chamber die-casting machine is suitable for low-melting-point

metals such as aluminum. After the molten aluminum is 

heated in a furnace, it is pushed into the mold by the piston

in the casting chamber. This process is suitable for 

producing thin-walled, high-precision aluminum castings.

Hot chamber die-casting machines suit high melting point metals

such as zinc. The molten metal is stored in a heating furnace

and injected directly into the mold by a mechanical device. 

This process is more suitable for producing a large number

of castings, but it is less suitable for aluminum.

3. Aluminum Die Casting Process

The process of aluminum die casting mainly includes the 

following steps:

3.1 Material Preparation

The selection of aluminum alloy materials is crucial. Commonly

used aluminum alloys include ADC12, A380, etc. Selecting 

the right alloy according to specific application requirements

can significantly improve the performance of castings.

The aluminum alloy is heated to the melting temperature in 

a furnace, usually around 660°C. The temperature needs to

be controlled during the melting process to prevent excessive

oxidation and quality loss of the aluminum alloy.

3.3 Injection

The molten aluminum is injected into the mold at high-pressure

through the injection system of the die-casting machine.

This process requires ensuring precise control of the 

injection speed and pressure to avoid the generation of 

bubbles and defects.

3.4 Cooling and demoulding

After the casting is cooled in the mold, it needs to be 

demoulded in time. The control of cooling time directly 

affects the size and precision of the casting.

3.5 Post-processing

After the casting is demolded, post-processing processes 

such as deburring, polishing, and surface treatment are 

usually required to improve the appearance quality and 

durability.

4. Application fields of aluminum die casting

Aluminum die casting has a wide range of applications, 

covering multiple industries:

4.1 Automobile industry

The automobile industry is one of the most widely used 

fields for aluminum manufacturing in die-casting machines. 

With the increasing demand for lightweight automobiles, the 

proportion of aluminum parts in automobiles is also gradually

increasing. 

For example, engine blocks, cylinder heads, transmission 

housings, wheels, and other body structural parts can be 

produced by die-casting machines. Due to the lightweight

characteristics of aluminum, the use of aluminum parts can 

not only reduce the weight of the car and improve fuel economy

but also improve the performance and safety of the car.

4.2 Electronic products

In the electronic and electrical industry, aluminum housings

radiators, and other parts are also widely produced by 

die-casting machines. Aluminum's good electrical and thermal

conductivity make it an ideal material for manufacturing 

components such as heat sinks, housings, and brackets for 

electronic devices. In addition, aluminum parts are also 

beautiful and durable and can meet the appearance and performance

requirements of electronic and electrical products.

4.3 Aerospace

The aerospace field has very high requirements for material

performance. Aluminum has become one of the most important 

materials in the aerospace field with its lightweight, high 

strength, and corrosion resistance. In the aerospace field, 

aluminum parts such as aircraft fuselage structural parts 

and engine parts are usually produced by high-performance 

die-casting machines to ensure product quality and reliability.

4.4 Home Appliances

Aluminum die-casting parts in many home appliances, such as

motor housings and brackets, use lightweight and strength

of aluminum to enhance product competitiveness.

Other fields

In addition to the above fields, the application of aluminum

manufacturing in die-casting machines also involves many 

fields such as construction, furniture, and toys. For example,

aluminum alloy doors and windows, curtain walls, and other parts

in the construction field, aluminum alloy frames in the 

furniture field and aluminum alloy toys in the toy field can 

all be produced by die-casting machines.

5. Advantages of aluminum manufacturing in die-casting machines

5.1 High production efficiency

Die-casting machines can realize automated production, and high 

production efficiency, and can meet the needs of large-scale 

production. Compared with traditional casting methods, die-casting

machines have a short production cycle and can quickly produce

high-quality aluminum products.

5.2 Good product quality

The die-casting machine adopts high-pressure injection molding,

which can fully fill the aluminum liquid in the mold cavity,

and the molded product has high dimensional accuracy and 

good surface quality. At the same time, the die-casting machine 

can also adjust the performance of the product, such as 

strength and hardness, by controlling the process parameters.

5.3 Products with complex shapes can be produced

The die-casting machine can produce aluminum products with 

complex shapes and high precision to meet the requirements 

of product shapes and sizes in different fields. By designing

a reasonable mold, the die-casting machine can produce various

complex geometric shapes, such as products with internal grooves,

bosses and other structures.

5.4 High material utilization rate

During the production process of the die-casting machine, the

utilization rate of aluminum liquid is high, which can reduce

material waste. At the same time, the die-casting machine can 

also realize the recycling of resources by recycling waste 

aluminum products.

6. Future development trend of aluminum die casting

With the development of science and technology and the changes

in market demand, aluminum die-casting technology is also 

constantly improving.

6.1 Application of new materials

More and more new aluminum alloy materials are being developed,

especially high-strength aluminum alloys. These materials 

can provide better mechanical properties while maintaining 

lightweight.

6.2 Automation and Intelligence

The automation level of die-casting machines is gradually 

improving, and the introduction of intelligent production 

lines makes the casting process more precise and efficient.

This will reduce labor costs and improve production efficiency.

6.3 Environmental protection and sustainability

Today, with the increasing awareness of environmental protection,

the recycling and green casting process of aluminum are 

valued. The development of environmentally friendly aluminum 

casting technology will help promote sustainable development

of the industry.

Conclusion

The application of aluminum manufacturing in die-casting 

machines have demonstrated their excellent performance and 

wide applicability. From automobiles to aerospace, to 

electronic products, aluminum die castings are increasingly

becoming an important part of modern manufacturing. With the

continuous advancement of technology and changes in the market

demand, the future of aluminum die casting is full of opportunities

and challenges. 

Through continuous innovation and optimization, 

the application of aluminum manufacturing in die-casting 

machines will make greater contributions to promoting the 

progress of industrial manufacturing and the development of 

social economy.

Hopefully, this article will provide you with an in-depth 

understanding of the use of aluminum in die-casting machines

and help you solve related problems. If you have more specific

questions, feel free to ask!

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