Aluminum die casting efficiently transforms molten aluminum into precisely shaped, high-strength metal parts. It's a mainstay in countless industries, delivering components with high dimensional accuracy, excellent surface finish, and excellent thin-wall performance. Understanding its core process is crucial for OEMs seeking reliable, cost-effective, and complex metal parts. There are two primary approaches to core aluminum die casting technology. Let's explore them with METALLECA.
Process:
Molten aluminum alloy is manually or automatically ladle from a separate holding furnace into a cold chamber within the machine. A hydraulically driven piston then presses the metal at high speed and pressure into a locked, water-cooled steel die cavity. Pressure is maintained until solidification occurs.
Advantages:
Efficient processing of high-melting-point alloys.
Particularly suitable for large castings.
Generally produces components with higher integrity and lower porosity, suitable for demanding applications.
Sleeve/piston life is longer than with hot chamber die casting.
Disadvantages:
Cold Aluminum Die Casting has lower cycle rates than hot chamber die casting.
The risk of oxide inclusions during ladle casting is slightly higher.
Precise control of the volume required to ensure consistency.
Process:
Primarily used for zinc, magnesium, and low-melting-point alloys. The injection mechanism is immersed in a pool of molten metal. As the plunger rises, the molten metal fills the gooseneck. The plunger then descends, forcing the metal under high pressure through the gooseneck nozzle into the die cavity. While technically possible for certain low-melting-point aluminum alloys, this is extremely rare due to the rapid corrosion of the immersed parts.
Advantages:
Hot Aluminum Die Casting offers extremely high cycle rates.
Excellent metal cleanliness due to the submerged feed method.
Highly efficient for small to medium-sized zinc parts.
Disadvantages:
Unsuitable for standard aluminum alloys due to corrosion of ferrous injection parts.
Shot volume is limited compared to cold chamber die casting.
| Feature | Cold Chamber Die Casting | Hot Chamber Die Casting |
| Molten Metal Feed | Ladled from separate furnace | Submerged injection mechanism |
| Primary Alloys | ADC12 (A383), A380, A360, A413 | ZAMAK 2, 3, 5, 7 |
| Melting Point | High (>~600°C / 1112°F) | Low (<~425°C / 800°F) |
| Typical Pressure | 15-150 MPa (2, 000-22, 000 psi) | 7-35 MPa (1, 000-5, 000 psi) |
| Cycle Speed | Medium to High | Very High |
| Part Size Range | Small to Very Large | Small to Medium |
| Metal Integrity | High (especially with enhancements) | High |
| Ideal For | Complex/High-Strength Al parts | High-Volume Zinc Parts |
