Aluminum die castings

Aluminum die castings are made by forcing molten alloy into a steel die under high pressure. They have thin walls, precise dimensions and a smooth surface, and are highly repeatable over a long series. That is why they are used wherever thousands of identical, lightweight parts are needed.

Where aluminum die castings are used

What sets die casting apart

• Thin walls and complex shapes – the metal fills the die under pressure, so a casting can include ribs, holes and bosses in a single part.
• Accuracy – dimensional tolerances often reach ±0.1 mm, and some surfaces require no machining.
• Smooth surface – a good base for powder coating.
• Repeatability – every casting in the series is made in the same die and with the same parameters.
• Alloys – most often EN AC-46200, EN AC-46500 and EN AC-47100, with very good castability.

There are limitations, too: the die is expensive, so the process pays off in large series, and die castings are usually not impregnated or welded. You can read more about cost-effectiveness and design on the page high-pressure die casting – when it pays off.

Finishing of High-Pressure Die Castings

1. Trimming – removal of the gating system, overflows and flash.
2. Deburring and Grinding – smoothing of edges and trimmed areas.
3. CNC machining – threads, fitted holes, sealing surfaces.
4. Powder coating – after degreasing, sandblasting or grinding, passivation and priming, in the full RAL color range.

High-Pressure Die Castings from Our Foundry

We produce high-pressure die castings in series of up to 100,000 pieces per year on an automated line with real-time process monitoring and full casting traceability. We make the dies in-house – we design them in CAD/CAM systems with mold filling simulation and machine them on our own CNC machines. Castings are machined and painted on site.

See also: aluminum high-pressure die casting – how it works, high-pressure die casting foundry i high-pressure die casting – our offer.