Aluminum Die Casting: Wide Applications and Promising Future
Application Fields
Aerospace Field
In space exploration-related equipment such as rockets, space shuttles, satellites, and aircraft and other flying vehicles, aluminum die-casting products are important internal components. For example, in Elon Musk's Starship project, although the launch failed, many parts used aluminum alloy die castings. The aerospace and aviation industries favor aluminum alloy die castings because they are lightweight in structure, high in strength, low in cost, and have better airtightness, shape complexity, ductility, and yield strength. For example, the turbine disk of an aircraft engine must have high strength and light weight, and the aluminum alloy die-casting process can produce high-quality turbine disks with complex shapes. The fuselage of the Airbus A380 is 44% aluminum alloy by weight, and the satellite shell is usually made of high-strength aluminum alloy die castings.
Communication and Electronic Field
In 2023, the global market sales of aluminum die castings for communication reached 6.8 billion US dollars, and it is expected to reach 9.7 billion US dollars in 2030. Aluminum die castings for communication mainly include components such as antennas, connectors, and housings. They have excellent electrical conductivity, heat dissipation, and electromagnetic shielding properties, making them very suitable for various communication applications.
Home Appliance Manufacturing Industry
Aluminum die-casting products are widely used in various home appliance accessories due to their light weight, rust prevention, waterproof, and low price characteristics. For example, some high-performance, high-precision, and high-toughness high-quality aluminum alloy die-casting products are also used in industries with relatively high requirements such as large aircraft and ships.
Precautions
Structural Design
Try to design as few structures with inclined tops as possible to prevent difficulties in removing burrs and flash later. Because after the die-casting of the inclined top structure, the operation of removing burrs is more difficult and it is easy to affect the quality and appearance of the product.
During structural design, it is also necessary to pay attention to the average thickness of the plastic and the smooth flow direction of the plastic. This can reduce many cases of poor appearance caused by molding and also reduce subsequent problems such as polishing and re-inspection. If the thickness of the plastic is uneven and the flow direction of the plastic is not smooth, it is easy to cause local defects in the product during the die-casting process, affecting the overall quality of the product.
If a softer grade is selected, the structural strength still needs to be considered when designing the load-bearing structure, otherwise it is easy to break. Different aluminum alloy grades have different performance characteristics. The soft grade aluminum alloy is relatively weak in strength. Therefore, when designing the load-bearing structure, its strength requirements need to be fully considered to ensure the safety and reliability of the product.
Advantages and Future Prospects of Aluminum Die Casting
Advantages of Aluminum Die Casting
Manufacturing of Complex Shaped Parts:
Aluminum die casting can manufacture metal parts with complex shapes, clear contours, thin walls, and deep cavities. The molten metal maintains high fluidity under high pressure and high speed, enabling the realization of metal parts that are difficult to process by other process methods. For example, in the manufacturing of key components such as automobile engine blocks and transmission housings, aluminum die casting can form complex structures in one step, eliminating the need for multiple assemblies or machining, greatly improving production efficiency and product quality.
High Dimensional Accuracy:
The dimensional accuracy of die castings is relatively high, reaching IT11 - IT13 levels, and sometimes even IT9 level. The surface roughness is Ra0.8 - 3.2μm, and the interchangeability is good. This gives aluminum die-casting products a significant advantage in applications that require fitting and assembly, such as electronic equipment housings and automobile parts.
High Material Utilization Rate:
Due to the high accuracy of die castings, only a small amount of machining is required before assembly and use, and some die castings can be directly assembled and used. The material utilization rate is about 60% - 80%, and the blank utilization rate reaches 90%. Compared with other manufacturing processes, it reduces material waste and lowers production costs.
High Production Efficiency:
Due to the high-speed filling, the filling time is short, and the metal solidifies quickly. The die-casting operation cycle is fast. Among various casting processes, the die-casting method has a relatively high productivity and is suitable for mass production. The domestic JⅢ3 horizontal cold air die-casting aluminum machine can die-cast aluminum 600 - 700 times on average in eight hours, and the small hot chamber die-casting aluminum machine can die-cast aluminum 3000 - 7000 times on average in eight hours.
Other Advantages:
It is convenient to use inserts. It is easy to set positioning mechanisms on the die-casting mold to facilitate the embedding of inserts and meet the special performance requirements of local parts of the die casting. At the same time, the aluminum alloy material has good thermal conductivity, strong plasticity, and noise reduction characteristics, making aluminum die-casting products widely used in the fields of heat dissipation and noise reduction of electrical components.
Future Prospects
Automotive Field:
With the development of the new energy vehicle industry and the increasing demand for lightweight, the integrated die-casting technology is gradually becoming the trend. Aluminum die casting plays an important role in automotive lightweight. The body structure parts, as the load-bearing parts in the car, have the characteristics of large size, thin wall, and complex structure. Die-casting technology has become one of the main ways of automotive lightweight. It is estimated that the market of aluminum alloy die castings for Chinese passenger vehicles will reach 175 - 200 billion yuan in 2025, and the compound annual growth rate of the market is expected to reach 11%.
Electronic and Communication Field:
In the communication and electronic field, aluminum die-casting products have excellent electrical conductivity, heat dissipation, and electromagnetic shielding properties. In 2023, the global market sales of aluminum die castings for communication reached 6.8 billion US dollars, and it is expected to reach 9.7 billion US dollars in 2030. With the development of 5G technology and the continuous upgrading of electronic products, the demand for aluminum die-casting products will continue to grow.
Other Fields:
In the fields of aerospace, home appliances, and construction, aluminum die-casting products also have broad application prospects. For example, in aerospace equipment such as aircraft and satellites, aluminum alloy die castings are lightweight in structure, high in strength, low in cost, and have better airtightness and shape complexity. In the home appliance field, aluminum die-casting products meet the needs of various home appliance accessories with their light weight, rust prevention, waterproof, and low price characteristics.
Technology Innovation Drive:
With the continuous progress and innovation of die-casting technology, such as the research and development of super-large die-casting machines, the application of new alloy materials, and the improvement of mold technology, the application fields of aluminum die casting will be further expanded. At the same time, the trend of environmental protection and energy conservation will also promote the development of the aluminum die-casting industry in the direction of green and low-carbon. The recyclability of aluminum alloy will make it play a greater role in sustainable development.
In conclusion, aluminum die casting has a wide range of application prospects in various fields with its numerous advantages. With the continuous progress of technology and the growth of market demand, the aluminum die-casting industry will have a broader development space.