An Introduction to Aluminum Die Castings

Aluminum die casting is a manufacturing process that involves heating and melting aluminum and pouring the molten material into steel casting molds (i.e., dies). After a sufficient cooling period, the material can retain the shape of the inner cavity of the mold and can be removed for further processing or use. The final components demonstrate a variety of advantages over parts and products made through other manufacturing methods. As a result, they find application in a wide range of industries and applications.

Benefits of Using Aluminum for Die Castings

Aluminum is one of the most commonly used metals in die casting processes. Some of the reason for this popularity include:

• Strength-to-weight ratio — Aluminum is strong but lightweight, allowing manufacturers to create lighter castings without sacrificing strength.
• Corrosion resistance — Aluminum is highly corrosion-resistant, which helps improve the durability of castings made from the material.
• Electrical/thermal conductivity — Aluminum is highly conductive, making it suitable for use in applications with electrical and thermal transfer requirements.
• Customizability — Aluminum is easy to customize, readily retaining many complex designs and forms.
• Alloy/grade selection — Aluminum is available in many alloys and grades, each of which offers slightly different characteristics. This broad selection provides manufacturers with greater freedom when choosing a material for their project. Examples of aluminum alloys used in die casting operations include A360, A380, A383, ZA-8, ZA-12, and ZA-27.

Applications of Aluminum Die Castings

Aluminum casting molds find use in numerous industries, including, but not limited to, the following:

Renewable Energy

In the renewable energy industry, the aluminum die casting process is used to produce various parts and products for power generation and distribution equipment. Examples include solar panel brackets, wind turbine parts, and more. As aluminum is lightweight, strong, and corrosion resistant, it is ideal for creating durable and reliable system components.

Aerospace

In the aerospace industry, aircraft must have components that are engineered for reliable performance. Otherwise, there is a risk of equipment failure in critical applications. The light weight, high durability, and relative affordability of aluminum die castings make them ideal for aircraft as they can withstand the harsh operating and environmental conditions and improve fuel efficiency at a lower cost than other manufactured components.

Agriculture

In the agricultural industry, aluminum die castings are integrated into many different machines, such as tractors and combine harvesters. The components offer durability and reliability, making them ideal for use in these demanding applications.

Recreational Vehicle

In the recreational equipment industry, a number of recreational equipment and vehicle parts are made using the aluminum die casting process. Examples of aluminum die cast recreational vehicle parts include structural and functional components (e.g., chassis, axles, counter mounts, and liner inserts) and cosmetic components (e.g., hood ornaments).

Military/Defense

In the military/defense industry, firearm manufacturers use die casting to create parts for commercial, law enforcement, and military pieces. Examples of aluminum die cast gun parts include trigger guards, Remington receivers, and other parts for rifles and shotguns.

Industrial Equipment

In the industrial equipment industry, aluminum die castings are used for various components of equipment and systems. Examples of die cast equipment components include bearings, connecting rods, and pistons.

Medical

In the medical industry, a variety of devices and systems use aluminum die cast parts. These components are integrated into everything from hospital beds to surgical devices to diagnostic and treatment equipment.

Consumer Products

In the consumer products industry, aluminum die castings are found in many consumer products. The components help ensure the finished products are lightweight and durable.

Contact the Aluminum Die Casting Die Experts at RAM Tool Today

Aluminum die castings are critical components of devices, equipment, and systems across a wide range of industries. However, they must be carefully designed and constructed to work as intended. Achieving this goal necessitates the use of a high-quality casting die. Fortunately, the experts at RAM Tool are here to help.

We specialize in the custom machining and building of aluminum and zinc die casting dies. Equipped with decades of machining and building experience and state-of-the-art manufacturing equipment, we have what it takes to deliver high-quality products for virtually any customer need. To learn more about our aluminum die casting die capabilities or discuss your die requirements with one of our experts, contact us today.