Per KG aluminum die casting cost ranges from roughly 4$ to 6$ USD. Similarly, Tooling cost can range from 8,000$ to 15,000$ USD.  If you have simple design, you can save $5,000-$10,000 in tooling costs. Moreover, right aluminum alloy like A380 can reduce up to 10% cost.

There are certain ways to make Aluminum die casting less expensive and profitable. In terms of this design optimization, cheaper alloys, recycled aluminum, etc., come first. Read more about how to reduce aluminum die-casting costs in this article. Learn where to focus to improve production results.

Optimize Die Design To Reduce Die Casting Cost

Importance of Die Design

Apparently, die designs have a critical role. As such, the design must create the right size parts, contain smooth surfaces, and offer sufficient strength. Besides this, the effective die design also takes less time per cycle and is impacted by repeated use.

Impact on Part Quality

Poor die designs bring along various problems. They are all minor issues to begin with and then eventually convert into inevitable defects like cracks, warping, or roughness.

For example, a die that’s unable to endure temperatures between 400-700°C causes defects.

Therefore, you need a more precise die design if you’re going to take down this issue.

Die casting cost Influence on Production Rate and Die Life

The impact that a well-designed die leaves on overall production includes reduced cycle times and longevity. For example, it can shift from 30 seconds to 25 seconds per part. Similarly, the production capacity increases by 20%. Consequently, it not only saves money but also improves efficiency.

Technical Aspects of Die Design

Gating Systems:

A gating system includes many other components. For example, spure, chokes, runners, and ingates.

In order to spread molten aluminum into dies, these parts are significant such as:

• The sprue is a fundamental channel with around 10-15 mm width.
• The choke helps metal flow more quickly with a width of 5-8 mm.
• Runners, 8-12 mm wide, let the metal cover each side of the die.
• Ingates, 3-6 mm wide, especially work for guiding the metal towards the die.

Venting Systems:

Venting systems work by incorporating cooling channels, ejector pins, draft angles, and parting lines. Their main job is to prevent air entrapment and reduce defects.

• Cooling channels (6-10 mm in diameter) release a sufficient amount of pressure to keep the die temperature at the right degree.
• Ejector pins are good to add every 50-100 mm to push out the final part.
• Draft angles with 1-3° let you remove parts easily.
• When parting lines do not fit perfectly, then the casting produces residue or flash around the edges.

Heat Transfer:

It’s important to maintain heat during casting. This is because uneven die cooling leads to shrinkage, cracks, and warping.

Also, proper cooling channels can fix this issue, as they maintain the die at the right temperature.

Optimizing Die Design to Reduce Aluminum Die Casting Cost

The benefits of simple parting lines, efficient cooling channels, and reduced die components could be one of the cut costs.

For example, a die with fewer parts can save around 5000-10000, while cooling systems save energy.

In addition to this, designing for manufacturability (DFM) creates an easy die design, improving its manufacturing ability and use.

Use of Simulation Software

Software like MAGMAsoft and ProCAST allows designers to locate weak areas and flow patterns. They predict the reason for problems like shrinkage or cracks before manufacturing. For instance, simulation integration in die designs results in saving materials waste up to 10-15% and making better parts.

Minimizing Complexity and Reducing Waste

Factors like undercuts and cores impact the die cost. So, in this case, make fewer undercuts and add simple cores to save time and money. Also, look for gating systems like tapered runners to prevent flash and scrap.

These techniques significantly save material waste and cycle time by up to 12%.

Select the Right Aluminum Alloy

Overview of Aluminum Alloys

Because of its lightweight, strong, and corrosion-resistant properties, manufacturers use aluminum alloys primarily. Their common types are A380, ADC12, and AlSi9Cu3.

Each of them is different as their chemical compositions are not the same. For example, A380 is composed of Al-8.5%Si-3.5%Cu and ADC12 with Al-10%Si-2.5%Cu.

Key Properties

As we have discussed above, aluminum alloys are produced by adding several elements.

This is why these elements affect their properties (tensile strength, yield strength, and ductility). For instance, there is ~310 MPa tensile strength in A380 alloys and 250°C thermal stability.

In addition to thermal stability, it is the parameter that shows how well the alloy works at high temperatures.

For example, the image shows the different aspects of Al-base and AlSi H13 hot alloys. They maintain strength up to 400-600°C, which is good to use in high-temperature parts.

Differences Between Primary and Secondary Alloys

You can differentiate primary and secondary alloys by their actual source. This is because primary alloys contain pure material, while secondary ones include recycled items.

The presence of trace elements like iron and manganese can change its properties. For example, an alloy with too much iron could have lower ductility.

Impact of Alloy Selection on Die Casting Costs

Material costs are not the same in every region or setup. So their prices keep fluctuating. For example, A380 is not much more costly than ADC12. Particularly, ADC12 has good fluidity. That, however, makes fewer defects in casting.

Likewise, complicated alloy options, including AlSi9Cu3, can cause tool wear and raise machining costs.

Cost Impact of Alloy on Die Lifespan

Some alloys, like AlSi H13 hot, offer excellent thermal stability. This is because they do not lead to die wear, increasing their performance cycles.

The proper alloy selection can bring a very reduced cost. This way, you can get specific features like part quality, extended die life, and easy production at better rates.

For example, the AlSi9Cu3 alloy is suitable for high strength but, at the same time, saves 10% on machining costs.

Improve Casting Process Efficiency

Overview of the Die-Casting Process

In order to produce product profile parts, manufacturers prepare molten aluminum. This material then shifts in an injection mold where it is pushed by force at high pressure.

The casting process includes contributions from other components, too. For example, mold, feeder tube, and ejector pins.

• The mold contains the profile shape.
• The feeder tube is like pathways that deliver metals
• Ejector pins aid in removing parts safely from the mold.

Methods of Die-Casting

Casting can be done in both hot and cold chambers. The selection between them lies in metal types and their melting points.

This is because hot chamber die casting cannot handle alloys with high melting points. It goes well with low melting points, like zinc.

However, in the case of higher melting points (aluminum), cold chambers work effectively.

Hot chambers take less time to complete one cycle, while cold chambers make parts stronger.

Methods to Improve Process Efficiency

Optimizing Temperature Control:

We already know controlling die temperatures is necessary. So, there are die heaters and cooling systems available to help. Also, real-time temperature monitoring produces parts with similar features or consistency.

Reducing Cycle Times:

Speed up the mold filling process and maintain injection pressure around 500-1500 bar. Optimize cooling times and the removal process in a way that can save 5-10 seconds per unit.

Implementing Automation:

Automation increases work efficiency and reduces costs. This is because robots are faster and make fewer errors than humans. They can be used to apply lubricants on the die, perform part extraction, and perform inspection steps.

Preventative Maintenance:

Regularly inspect each machine’s equipment and its supportive parts. Check for any breakdown and replacement needs. This maintenance support keeps the setups running.

So, the key aspects of improving die casting really help you in getting cheaper production.

Reduce Material Waste

Importance of Reducing Material Waste

Material waste is not good for environmental conditions or for cost savings. For example, the waste of aluminum chips causes serious harm if not reused. Additionally, scrapes need more energy to remelt and process. Production costs increase as a result.

Methods to Minimize Waste

1.   Optimizing Die Design:

You need to optimize runners and gate systems in order to reduce waste. At the moment, pick smaller runners and gates.

For example, shift the size of the gate from 6 mm to 4 mm. It uses less material, saving 10% on scraps.

Also, there is the option to optimize overflow by capturing excess metal for reuse.

2.   Implementing Recycling Programs:

This kind of aluminum chip waste can be recycled in-house using a hot extrusion machine. Meanwhile, complex waste like EDM wire or compact extrudate needs external recyclers.

3.   Reducing Overproduction:

Demand forecasting and lean manufacturing principles aid in fixing excess inventory. They design parts using materials of the actual quantity.

4.   Proper Melt Handling:

Ultrasonic baths help in removing oxidation from aluminum’s surfaces before melting. Which, therefore, produces less waste, cutting it by 5-10%.

Material waste reduction via process and die design helps companies save more and protect the environment.  These techniques also promote sustainability. For example, reusing aluminum chips can save $10,000 per year.

Consider Alternative Manufacturing Methods

Overview of Alternative Manufacturing Methods

Apparently, there are several techniques used to make parts with specific features. For example, 3D printing, machining, investment casting, and metal injection molding. Each method has particular pros and cons.

Advantages and Disadvantages Compared to Die Casting

• 3D Printing: Works best for making difficult-shaped parts and fewer quantities but is too slow for big orders.
• Machining: Give accuracy in part, adding precise details but generating material waste.
• Investment Casting: Capable of producing sharp detail parts but costs much more for mass production.
• Metal Injection Molding: Small-size complex parts can be made using this process. However, it handles certain alloys.

Alternative Methods to Reduce Costs of Aluminum Die Casting

1. Reduced Material Waste: 3D printing works effectively when taken in a near-net shape. It cuts waste by up to 20-30%.
2. Lower Tooling Costs: 3D printing does not need complex tooling and cuts down setup costs by $10,000-$50,000.
3. Increased Design Flexibility: 3D printing can make products with the most challenging features. So, there is no need for parts to add other components.

Conclusion

The aluminum die casting cost reduction solution lies in different factors. That includes die designs, suitable alloys, process efficiency improvement, and waste reduction.

Also, alternative methods like 3D printing save more. Optimize these parameters accordingly to get efficient production at a lower price. Reach out to us to see the actual results.