Aluminum Die Casting Services
Looking for Aluminum Die Casting solutions or curious about Aluminum Die Casting costs? IEC MOULD offers high-quality Aluminum Die Casting technology and cost-effective casting services tailored to your needs. Whether you need precision components or large structural castings, our expertise covers it all—get in touch today!
Aluminum Die Casting – Lightweight, Durable & Cost-Efficient Solutions
Aluminum die casting is one of the most widely used and versatile metal casting processes in modern manufacturing. Thanks to its lightweight properties, excellent strength-to-weight ratio, superior corrosion resistance, and outstanding design flexibility, aluminum has become the preferred material for industries ranging from automotive and aerospace to consumer electronics and medical equipment.
At IEC Mould, we provide end-to-end aluminum die casting solutions, covering DFM (Design for Manufacturability), mold flow simulation, mold design & manufacturing, high pressure die casting (HPDC), CNC machining, surface finishing, assembly, and quality inspection. With decades of experience and advanced manufacturing facilities, we help engineers, procurement specialists, and quality managers achieve cost efficiency, precision, and long-term reliability in their projects.
What is Aluminum Die Casting?
Aluminum die casting is a manufacturing process in which molten aluminum alloy is injected into a steel mold cavity under high pressure. Once solidified, the part is ejected from the die, resulting in a highly accurate, durable, and repeatable component.
Unlike other manufacturing methods such as machining, forging, or sand casting, aluminum die casting offers:
- Complex geometries with thin walls
- Tight tolerances for high-precision applications
- Fast cycle times for high-volume production
- Cost savings through reduced machining and assembly steps
This makes it the go-to process for industries that require lightweight yet strong metal parts at competitive costs.
Why Choose Aluminum for Die Casting?
Aluminum is one of the most versatile and widely used die casting metals. Its unique combination of strength, lightness, and recyclability makes it the material of choice across multiple industries.
Key Benefits of Aluminum Alloys in Die Casting:
- Weight Reduction: Up to 33% lighter than zinc and 75% lighter than steel.
- High Strength-to-Weight Ratio: Suitable for structural and safety-critical applications.
- Corrosion & Weather Resistance: Excellent for outdoor and marine applications.
- Thermal & Electrical Conductivity: Used extensively in electronics and EV battery housings.
- Recyclability: 100% recyclable with minimal property degradation.
🔧 Compared to Magnesium: Aluminum is slightly heavier but offers better strength and corrosion resistance.
🔧 Compared to Zinc: Aluminum is lighter, handles higher temperatures, and is better for large components.
How Does Aluminum Die Casting Process Work?
As a leading aluminum die casting manufacturer, we understand the importance of precision, alloy selection, and process control in delivering high-quality cast components. Whether you need lightweight structures, excellent heat dissipation, or durable and corrosion-resistant parts, a well-defined die casting process is the key to success.
Below, we outline the typical five-step aluminum die casting workflow followed by every reliable foundry. This streamlined approach ensures optimal filling, consistent part performance, and cost-effective scalability across automotive, aerospace, electronics, and industrial applications.
Step 1: Alloy Melting & Preparation
The process begins with melting aluminum ingots or recycled aluminum scrap in a controlled furnace. At this stage, alloying elements such as magnesium, copper, or silicon may be added to enhance strength, corrosion resistance, or thermal conductivity.
- Engineer’s view: Alloy consistency ensures predictable mechanical properties and dimensional accuracy.
- Procurement’s view: Efficient use of recycled aluminum lowers material costs while maintaining sustainability.
- Quality control’s view: Impurity removal and proper temperature monitoring prevent porosity, cracks, and weak points in the final casting.
Step 2: Die & Mold Preparation
Before casting, the steel die (mold) is preheated and coated with a release agent. Preheating prevents thermal shock, while coatings extend mold life and improve surface finish.
- Engineer’s view: Proper mold design with cooling channels supports thin walls, complex geometries, and tight tolerances.
- Procurement’s view: A well-maintained die reduces downtime and ensures longer tooling life, optimizing total cost of ownership.
- Quality control’s view: Correct mold preparation minimizes surface defects such as blistering, cold shuts, or flow marks.
Step 3: High-Pressure Injection Casting
Once prepared, molten aluminum is injected into the die cavity under high pressure (up to 100–150 MPa). This rapid injection ensures complete cavity filling, even for intricate designs and thin walls.
- Engineer’s view: High pressure delivers superior strength-to-weight ratio and excellent repeatability across large production volumes.
- Procurement’s view: Short cycle times (often 30–60 seconds) improve productivity and reduce per-unit cost.
- Quality control’s view: Consistent pressure control reduces porosity, ensuring reliability in safety-critical applications such as automotive or aerospace.
Step 3: High-Pressure Injection Casting
Once prepared, molten aluminum is injected into the die cavity under high pressure (up to 100–150 MPa). This rapid injection ensures complete cavity filling, even for intricate designs and thin walls.
- Engineer’s view: High pressure delivers superior strength-to-weight ratio and excellent repeatability across large production volumes.
- Procurement’s view: Short cycle times (often 30–60 seconds) improve productivity and reduce per-unit cost.
- Quality control’s view: Consistent pressure control reduces porosity, ensuring reliability in safety-critical applications such as automotive or aerospace.
Step 5: Trimming & Surface Finishing
Once the aluminum part is ejected, excess material such as flash, runners, and gates is carefully trimmed. Depending on functional or aesthetic requirements, the components can undergo a variety of surface finishing processes, including:
- CNC machining for tight tolerances
- Shot blasting or tumbling for smoother surfaces
- Anodizing for corrosion resistance
- Powder coating or painting for durability and appearance
- Assembly of multiple die cast components into complete units
- Engineer’s view: Post-processing ensures precise tolerances and enables customized surface finishes for performance and design needs.
- Procurement’s view: Having trimming and finishing in-house shortens lead times and avoids outsourcing costs.
- Quality control’s view: Controlled finishing processes minimize variability and ensure consistent surface quality.
Step 5: Quality Inspection & Testing
Every batch of aluminum die cast parts undergoes strict quality control measures to guarantee compliance with customer and industry standards. Typical testing methods include:
- X-ray inspection for internal porosity or defects
- CMM (Coordinate Measuring Machine) for dimensional accuracy
- Leak testing for sealing and pressure integrity
- Mechanical property testing for tensile strength, hardness, and elongation
- Engineer’s view: Testing ensures structural integrity and reliability, especially for safety-critical parts in automotive and aerospace industries.
- Procurement’s view: Verified quality reduces risk of rework, warranty claims, and supply chain disruptions.
- Quality control’s view: Meeting ISO, IATF 16949, or aerospace standards reinforces compliance and customer trust.
How to choose right Aluminum Alloys for Die Casting?
Choosing the right aluminum alloy is one of the most critical decisions in die casting. Each alloy offers a different balance of strength, corrosion resistance, machinability, and thermal properties. At IEC Mould, we work with all major aluminum die casting alloys, helping customers select the perfect match for their design and application requirements. Check the Common Aluminum Alloys Used in Die Casting as below.
A380 (AlSi8Cu3Fe)
- The most widely used aluminum die casting alloy.
- ✅ Excellent balance of strength, weight, and cost.
- ✅ Good corrosion resistance and machinability.
- ✅ Excellent pressure tightness and dimensional stability.
Applications: Automotive housings, gearboxes, electronics enclosures.
ADC12 (Al-Si-Cu family)
Equivalent to A383 in many markets.
- ✅ Superior corrosion resistance compared to A380.
- ✅ Good castability for thin-wall, complex shapes.
- ✅ High fluidity with excellent filling properties.
Applications: Engine parts, transmission housings, laptop housings.
AlSi9Cu3
Popular in European automotive and engineering industries.
- ✅ Very high mechanical strength.
- ✅ Excellent wear resistance.
- ✅ Strong performance in high-temperature environments.
Applications: Cylinder heads, turbocharger housings, heavy-duty automotive parts.
A413 (AlSi12)
- ✅ Excellent corrosion resistance and fluidity.
- ✅ High-pressure tightness, ideal for hydraulic components.
- ✅ Smooth surface finish, suitable for anodizing.
Applications: Hydraulic cylinders, pump housings, marine equipment.
A360 (AlSi10Mg)
- ✅ Better corrosion resistance than A380.
- ✅ Excellent ductility and toughness.
- ✅ Good heat resistance.
Applications: Aerospace brackets, electronic housings, outdoor lighting.
Aluminum Alloy Selection Guide
| Alloy | Key Strength | Weakness | Typical Use Cases |
|---|---|---|---|
| A380 | Balanced strength, cost-effective | Lower corrosion resistance | Automotive, electronics housings |
| ADC12 | High corrosion resistance, good castability | Slightly lower strength | Thin-wall, consumer electronics |
| AlSi9Cu3 | High strength, high-temp resistance | Higher cost | Engine parts, turbochargers |
| A413 | Best corrosion resistance | Not as strong as AlSi9Cu3 | Hydraulic, marine |
| A360 | High ductility, corrosion resistance | More difficult to cast | Aerospace, outdoor |
Aluminum vs. Other Die Casting Metals
| Property | Aluminum | Magnesium | Zinc | Brass |
|---|---|---|---|---|
| Weight | Light | Very light | Heavy | Heavier |
| Strength | High | Moderate | Moderate | Very high |
| Corrosion Resistance | Excellent | Good | Good | Excellent |
| Cost Efficiency | High (volume) | Moderate | High (small parts) | Higher |
| Applications | Auto, aerospace, electronics | Portable devices | Small precision parts | Valves, fittings |
Aluminum Die Casting Parts in Different Industries
Aluminum Die Casting is a versatile manufacturing process widely adopted across multiple industries for its unique balance of strength, lightweight, and cost efficiency. From automotive and aerospace to electronics, industrial equipment, and consumer products, aluminum die casting enables the production of complex, high-precision components with excellent thermal conductivity, corrosion resistance, and dimensional stability. This process allows to create durable parts that meet strict performance standards while reducing weight and optimizing overall system efficiency.