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Aluminium die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

Aluminium die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Aluminium die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.

History of Aluminium Die Casting:

The earliest examples of die casting by aluminium pressure injection-as opposed to aluminium casting by gravity pressure-occurred in the mid-1800s. A patent wasa warded to Sturges in 1849 for the first manually operated machine for casting printing type. The process was limited to printer’s type for the next 20 years, but development of others hapes began to increase toward the end of the century. By 1892, commercial applications included parts for phonographs and cash registers, and mass production of many types of parts began in the early 1900s.

The first aluminium die casting alloys were various compositions of tin and lead, but their use declined with the introduction of zinc and aluminium die casting alloys in 1914. Magnesium and copper alloys quickly followed, and by the 1930s, many of the modern alloys still in use today became available.

The aluminium die casting process has evolved from the original low-pressure injection method to techniques including high-pressure casting - at forces exceeding 4500 pounds per square inch - squeeze casting and semi-solid die casting. These modern processes are capable of producing high integrity, near net-shape castings with excellent surface finishes.

Future of Aluminium Die Casting:

Refinements continue in both the alloys used in die casting and the process it self, expanding aluminium die casting applications into almost every known market. Once limited to simple lead type, today’s die casters can produce castings in a variety of sizes, shapes and wall thicknesses that are strong, durable and dimensionally precise.

Advantages of Aluminium Die Casting:

Aluminium die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Parts have long service life and may be designed to complement the visual appeal of the surrounding part. Designers can gain a number of advantages and benefits by specifying die cast parts.

High-speed production - Aluminium die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required. Dimensional accuracy and stability - Aluminium die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant. Strength and weight - Aluminium die casting parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because aluminium die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.

Multiple finishing techniques - Aluminium die casting parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation. Simplified Assembly - Aluminium die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.

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