Choose DSR – Superior Aluminum Die-casting Parts Manufacturer
Aluminum die-casting uses high-pressure injection of molten aluminum into a mold to rapidly produce complex, high-precision parts. Compared to other processes, it can achieve thinner wall thicknesses, making it ideal for high-volume production.
DSR utilizes a variety of advanced die-casting machines and skilled craftsmen. With a staff of nearly 100, including 15 senior engineers, we ensure rapid mold creation and order fulfillment.
Whether you’re working in the automotive, agriculture, medical, aerospace, energy, or other industries, DSR can provide the right aluminum die-cast parts. We can also customize the processing to enhance part performance and service life.
Contact us now for a quote. We offer first-time order discounts and lower unit prices for larger quantities.
Various Aluminum Parts We Can Die Cast For You
Aluminum housings suitable for various diesel engine pumps have short production cycles, low unit prices, and good thermal conductivity.
Aluminum parts used in the automotive industry, die casting technology creates thinner walls and a high-quality surface finish.
Providing you with high-quality ADC12 aluminum, high-pressure die-casting of various parts and housings, allowing you to enjoy OEM metal processing services at a very high cost-effectiveness.
Combining CNC milling and aluminum die-casting to manufacture automotive engine components allows for tighter tolerances and higher surface quality, making your automotive project stand out.
Using advanced vacuum die-casting services to manufacture various aluminum parts with complex structures for you, providing you with a one-stop aluminum parts processing solution.
DSR provides you with one-stop OEM customization services, from mold design to door-to-door delivery, allowing you to experience the best aluminum die-casting solutions.
Aluminum cookware is one of the most widely used cookware. Custom DSR aluminum die-casting process makes high-quality cookware a success for your brand in commercial kitchens and homes.
Using aluminum die-casting technology to customize stators and rotors for various compressors, and provide subsequent trimming and deburring services to create high-quality and high-precision parts.
All Kinds Of Die Casting Methods DSR Can Provide
Cold Chamber Die CastingMolten aluminum is heated in an external furnace and poured into a cold chamber via a bucket or channel. It is then injected into the mold at high speed by a piston.
High-Pressure Die CastingUsing pressures ranging from tens to hundreds of MPa, rapid injection is used. This method is suitable for mass production, complex parts, and thin-walled components, achieving high precision and surface quality.
Low-Pressure Die CastingMetal is injected through the bottom of a pressure-maintaining furnace at low pressure (approximately 0.1–1 MPa). This method is suitable for large or complex structural parts, offering slow flow and low defect rates, but with longer cycle times.
Vacuum Die CastingAir is evacuated from the mold before and after injection, significantly reducing porosity and improving density and mechanical properties. This method is suitable for demanding applications (such as hydraulic and airtight parts).
Gravity CastingMolten aluminum is injected into a steel mold by gravity without applying an injection force. This method is suitable for medium-volume production. Its precision is lower than that of die casting.
Shell CastingLike the lost wax method, a wax pattern is first formed, coated with ceramic, and then dewaxed before metal is poured. This method is suitable for aluminum parts with complex shapes and high precision requirements.
Lost Foam CastingUses a foam pattern instead of a wax pattern. The foam is melted or burned off, and molten aluminum is directly filled in. This method is suitable for complex structures or small to medium-sized batch production.
Advantages of DSR Aluminum Die Casting Service
High-pressure injection molding enables filling and solidification, significantly reducing production cycles and making it suitable for high-volume, continuous production.
The mold can be reused multiple times, reducing unit production costs and accommodating long-term, stable production schedules.
Injection die casting can achieve extremely low tolerances (e.g., IT10–IT15), thereby significantly reducing the need for subsequent machining.
Due to the delicate mold shaping, the finished product has a high finish and often requires no additional processing before shipment.
Thin-wall and complex structures can be achieved, and parts that are difficult to form using other processes can be extruded in one go. Applications include engine casings and electronic product frames.
Aluminum’s inherent low density while maintaining excellent strength makes it suitable for lightweight designs.
Aluminum die casting offers corrosion resistance, excellent thermal and electrical conductivity, and structural stability, making it suitable for use in complex environments.
A variety of surface treatments are available, including sandblasting, anodizing, electroplating, and powder coating, to meet diverse aesthetic and functional requirements.
Different Aluminum Alloy Materials We Use
The most widely used die-casting alloy, it offers excellent castability and dimensional stability, moderate strength, good thermal conductivity, and easy machining, making it suitable for a variety of structural parts and tool housings.
Described as “easier to cast,” it offers slightly better corrosion resistance than A380 and is suitable for delicate structural parts such as engine mounts.
Offers good flowability, excellent compaction properties, strong corrosion resistance, and good toughness, making it suitable for demanding applications such as instrument housings and thin-walled parts.
Offers high hardness and excellent wear resistance, but lower ductility, making it suitable for high-load, wear-resistant parts such as engine parts.
Offers excellent airtightness and is often used in components requiring pressure-resistant sealing.
Similar to A383, it is often used for precision structural parts, offering excellent weldability and enhanced corrosion resistance.
Its high ductility, strength, and corrosion resistance make it suitable for automotive components and aerospace applications.
General Steps in Aluminum Die Casting
Mold Design and Fabrication
Design and fabricate the two halves of a metal mold (usually a steel mold), including the cavity, runners, venting slots, and other structures. Clean, lubricate, and preheat before use to prevent thermal cracking.
Material Preparation
Select an appropriate aluminum alloy and heat the aluminum alloy ingot to its melting point, converting it into liquid metal.
Injection Casting
Molten aluminum is injected into the mold cavity at high pressure (cold chamber die casting machines are commonly used for aluminum) to ensure complete and rapid filling. Pressures typically range from tens to thousands of bars.
Cooling and Solidification
After injection, the metal rapidly cools and solidifies within the mold, achieving the desired shape. Temperature control is used to minimize distortion and porosity.
Mold Opening and Demolding
The mold is opened, and the casting is removed using an ejector. The mold closing and ejection processes require precise control to avoid damage to the blank.
Trimming and Deburring
Excess material, such as flash and sprues, is removed, and burrs are trimmed to improve dimensional accuracy and appearance.
Post-Processing and Surface Treatment
After the shape is finalized, machining, polishing, painting, electroplating, or other surface treatments are performed based on the part’s requirements.
Making hard steel molds requires extremely high process requirements, resulting in expensive equipment procurement and maintenance costs, making them amortizable only for large-scale production.
Mold design and modification cycles are lengthy, making it unsuitable for small-batch or rapid iteration production.
Aluminum die casting is not suitable for high-melting-point or iron-based metals, limiting material selection.
Due to injection pressure and mold complexity, conventional aluminum die casting struggles to meet large-part production requirements.
Complex structures, deep cavities, or slender parts can make flow path design difficult or lead to defects.
6061 and 6063 are common aluminum alloys, but neither is economically nor technically suitable for die casting.
They have high solidification shrinkage, which can easily lead to defects such as shrinkage cavities and porosity within the casting during the die casting process.
They have a high tendency to hot cracking, which can easily cause hot cracking during the solidification of the molten metal.
The high iron content can easily react with the iron in the mold at high temperatures, causing adhesion to the mold.
The poor fluidity makes it difficult to perfectly fill complex, thin-walled mold cavities in a short time.
