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When developing high pressure die cast parts, there are often requirements for complex geometry, relatively low weight and strength. Particularly in the case of thin wall thicknesses or parts with multiple functional surfaces, the choice of material is essential to achieving the desired result.
Aluminium is one of the most frequently used materials in high pressure die casting because of its low density, strength and flow properties within the tool. The material is ideal for both technical parts and products where design and functional requirements must be aligned.
In aluminium high pressure die casting, molten metal is injected into a tool under high pressure. The tool is filled quickly and accurately, making it possible to produce detailed geometric shapes during the casting.
Once the tool cavity is filled, the pressure is maintained during solidification to ensure that the material retains its shape. The parts is then cooled before ejection from the tool and sent on to the next stage of production.
Molten aluminium has excellent flow properties, enabling the material to fill tools even with thin sections and complex shapes.
Different aluminium alloys are used depending on the requirements, for example to meet requirements for corrosion resistance or strength. The choice of alloy affects how the material behaves during filling, pressure maintenance and cooling.
The interplay between the material’s properties and the tool’s design is key for controlling how the melt fills the tool, solidifies and retains dimensions. When these factors are properly matched, a controlled casting process with high-quality parts is achieved.
As mentioned earlier, the flow properties of aluminium make it possible to cast parts with complex shapes and thin wall thicknesses directly in the high pressure die casting process. This reduces the need for multiple individual parts.
High pressure die casting of aluminium is suitable for both production and prototyping, where the same part is manufactured in large quantities. In the long term, the high pressure die casting process contributes to cost-effective production costs in relation to part price.
High pressure die casting is an effective method for producing prototypes that have the same properties as the final parts. This makes it possible to test them for factors such as wear and market potential before making a bigger investment.
Aluminium combines low weight with excellent mechanical properties. Therefore, it is suitable for applications where both strength and weight optimisation are important.
Aluminium is a good choice when parts require a combination of complex shapes and good strength. It is often used in parts where multiple functions need to be integrated into a single part without making it unnecessarily heavy.
For applications where very tight tolerances and smaller parts are key, high pressure die casting in zinc is a good alternative. If you need parts with even lower weight, high pressure die casting in magnesium is the right choice. It has a lower density and provides a nice finish.
After high pressure die casting, the parts can be processed further to achieve tight tolerances and meet specific surface finish requirements. This is typically done using CNC machining, where the parts are machined with high precision across multiple axes. The combination of high pressure die casting and CNC machining ensures both efficient production and a high-quality end result.
We can help you decide whether aluminium is the right choice for high pressure die casting, based on your design and requirements. Get in touch and we’ll review your project and find a solution that meets your needs.