High strength aluminum die casting alloys

What is High-strength aluminum die-casting alloys

High strength aluminum die casting alloys are specialized aluminum alloy materials designed for high pressure die casting manufacturing process, this manufacturing process that involves forcing molten metal alloys into a die casting tooling under high pressure. These special designed alloys are engineered to provide excellent mechanical properties, including high strength, lightweight, corrosion resistance, and good thermal conductivity. They are widely used in industries like automotive, aerospace, electronics, and industrial machinery.

Normal high strength aluminum die casting alloys like A380, Aluminum Alloy A383, Aluminum Alloy A360, but if you are looking for high strength like aluminum 6061, 2024, A 7075 products which can be made by high pressure die casting process, then one of our special aluminum casting alloys will be one your best options. Below are some special characteristics for this high strength aluminum alloys, if this special casting alloys can improve your die casting products, welcome to contact us.

Basic features for this high strength die casting aluminum alloys：

1. The highest strength die-cast aluminum alloy in the die-casting industry, it can be used to replace stainless steel precision castings, powder metallurgy structural parts, and outdoor structural parts that require high load-bearing and corrosion resistance (replacing some steel components or aluminum forging casting products)
2. It has the characteristics of efficient production, lightweight, high corrosion resistance and high cost performance;
3. High yield strength and high elongation can be achieved in the die-cast state without heat treatment, and the yield strength after heat treatment is as high as 350Mpa 

Below table are some key difference between this high streangth aluminum casting alloy and stainless steel.

High strength aluminum casting alloys VS Sainless steel		Density (g/cm3）	tensile strength/Yield Strength /Elongation	Thermal conductivity	Key advanced Features
				W/m.k
Our High strength die casting aluminum	Aludie alloy	2.86-3.05	>310 Mpa/260-290 Mpa /2.0-3.5%	90-105	It can be used in high pressure die-casting process, which is simple and can save processing costs to the maximum extent compared with precision aluminum casting, powder metallurgy and liquid aluminum die forging. It also has excellent subsequent processing and cutting performance, can achieve diversified surface treatment, and can also be used as a heat sink.
	（Natural aging）
	Aludie alloy		>360 Mpa/290-350 Mpa/2.5-5.0%
	（T6）
Stainless steel	SUS304	7.93	Yield Strength>205Mpa，Elongation:40%	17
			tensile strength>520Mpa	（Ordinary steel 36-54W/m.k）
Advantages comparing to stainless steel and other similar aluminum alloys include ADC 12, A380,A360		62% more light weight than stainless steel	It can reach or exceed the strength and toughness required by some structural stainless steel products or forged aluminum products, and has good thermal conductivity	High electrical and thermal conductivity

Advantages of this high strength aluminum casting alloys

1. This high strength aluminum alloys have a high yield strength. The aluminum die casting made with this special aluminum alloy, natural aging can reach and exceed the yield strength of stainless steel. After T6 heat treatment, it can reach the yield strength of ordinary carbon steel. Therefore, it is widely used in many applications of cast iron, cast steel or forged aluminum parts.
2. This high strength aluminum alloys have good fluidity and easy to make with high pressure die-casting process. Therefore, compared with cast steel and cast iron, it has the characteristics of high-efficiency and high-precision molding, compact die-casting structure and strong stability, and has lightweight characteristics. The manufacturing quality product rate is much better than that of cast steel and cast iron.
3. Compared with powder metallurgy parts, the organization of this high strength aluminum die-casting products is uniform and dense, macro defects can be effectively controlled, the actual test failure threshold of the product is higher than that of powder metallurgy parts, the product deformation is small, the processing efficiency is high, and the product consistency is excellent. Our high strength aluminum alloy have a high level of yield strength, so when T6 treatment is carried out, the product will not produce stress deformation, and its skeleton organization can release the effect stress by itself.
4. Compared with forged aluminum parts, this high strength aluminum alloy is formed in one time, which has obvious production cost advantages for complex or special-shaped structures.

Case study with high strength die casting aluminum:

1. Hook (Large LED connection support hook)

Before this type of hook  precision casting stainless steel + CNC manufacturing, strict size requirements, single load-bearing 350kg without deformation, CSY22 precision die-casting does not need CNC, can meet the structural size requirements, can bear 500kg, no deformation for 72 hours

2. lock tongue (three Lock accessories products connected into one solid part)

The lock tongue made of the original stainless steel precision casting has a shear resistance of 6500N according to the national standard. After being precision molded by high strength aluminum die-casting alloy, the actual shear resistance exceeds 7500N, which is deformed compared with the original stainless steel precision casting’s actual measured shear resistance of 7200N.

3. Lock gear (lock accessories)

The original powder metallurgy lock parts fork gear had a standard torque resistance of 50NM, but after the casting parts made with this high strength aluminum die-casting alloy, the torque exceeded 60NM.

4. garden shears with long handles

The original A356 alloy garden shears handles made of liquid mold had a bending standard of 83kg*450mm. After being die-casted with our high strength aluminum alloy and treated with T6, it reached 105kg*450mm.

There are many aluminum product that need high strength alloys which mostly made in hot forging, gravity casting, which will have high production cost, with our special high strength die casting aluminum, we can use high pressure die casting process instead of hot forging, in that case could save lots of production cost, specially in high volume.

5. Aluminum door hinges

The original stainless steel door hinges were required to be tested for life of no less than 10,000 times without damage. When the door hinges of the same structure were tested for torsion and longitudinal and transverse bearing capacity under the same conditions, the aluminum alloy door hinges made of high strength aluminum alloys material did not deform after 10,000 torsion tests.

There are many aluminum product that need high strength alloys which mostly made in hot forging, gravity casting, which will have high production cost, with our special high strength die casting aluminum, we can use high pressure die casting process instead of hot forging, in that case could save lots of production cost, specially in high volume.

GC Mould is one of top 10 aluminum die casting manufacturers in China that offers custom die casting from aluminum, zinc, magnesium, copper, and some special aluminum alloys, if you are looking for high strenght aluminum die casting alloys for your die casting project, welcome to contact us.