Aluminum die casting is a casting method that efficiently manufactures products with complex shapes by injecting molten aluminum alloy into a mold at high speed and high pressure. It is used in a wide range of fields such as automobile parts, home appliances, and industrial equipment. The quality of aluminum die-cast products is greatly affected by material selection. By selecting the appropriate material, it is possible to optimize product strength, accuracy, thin-walledness, cost, recyclability, and more. This article explains the characteristics of typical aluminum alloys used in aluminum die casting and how to select the optimal alloy according to product applications, required characteristics, and usage environments. By understanding the points of material selection, higher quality and higher performance aluminum die-cast products can be realized.
Representative Alloys Used in Aluminum Die Casting and Their Properties
The representative alloys used in aluminum die casting and their properties are summarized in the table below.
| Alloy Name | Main Components | Mechanical Properties | Physical Properties | Chemical Properties | Applications | Characteristics |
|---|---|---|---|---|---|---|
| ADC12 | Al-Si-Cu series | Tensile strength: 230-300MPa Elongation: 1-2.5% Hardness: HB 80-120 |
Density: 2.7g/cm³ Melting point: 600-640℃ Thermal conductivity: 167W/mK |
Corrosion resistance: Good Heat resistance: Moderate |
Automotive parts, home appliances, industrial equipment | Good balance of castability, mechanical properties, and corrosion resistance |
| ADC10 | Al-Si-Cu series | Tensile strength: 240-280MPa Elongation: 1-2% Hardness: HB 85-110 |
Density: 2.7g/cm³ Melting point: 580-620℃ Thermal conductivity: 150-170W/mK |
Corrosion resistance: Good Heat resistance: Moderate |
Automotive parts, home appliances | Higher strength than ADC12, but poorer castability |
| ADC3 | Al-Cu series | Tensile strength: 250-300MPa Elongation: 1-1.5% Hardness: HB 90-120 |
Density: 2.8g/cm³ Melting point: 580-620℃ Thermal conductivity: 140-160W/mK |
Corrosion resistance: Moderate Heat resistance: High |
Aircraft parts, engine parts | High strength, heat resistance |
| A380 | Al-Si-Cu series | Tensile strength: 310MPa Elongation: 1-2% Hardness: HB 90-120 |
Density: 2.7g/cm³ Melting point: 570-610℃ Thermal conductivity: 150-170W/mK |
Corrosion resistance: Good Heat resistance: High |
Automotive parts, electronic equipment | High castability, heat resistance |
| ADC1 | Al-Si series | – | – | – | Automotive, building materials | – |
| ADC5 | Al-Mg series | – | – | – | Outboard motors, agricultural equipment, fishing equipment | – |
| ADC6 | Al-Mg series | – | – | – | Motorcycles, outboard motors, golf equipment | – |
| ADC14 | Al-Si-Cu series | – | – | – | Automotive, motorcycles | – |
Supplement
- The table above is an example of typical alloys, and there are many other types of alloys.
- The properties of each alloy vary depending on the composition and manufacturing conditions.
- It is important to select the optimal alloy according to the application.
- Please consult with a specialist for more detailed information.
Alloy Property Comparison Table
When comparing and considering the properties of each alloy, it is helpful to pay attention to the following points.
- Mechanical Properties: Strength, toughness, hardness, fatigue strength, etc.
- Physical Properties: Density, thermal conductivity, thermal expansion coefficient, etc.
- Chemical Properties: Corrosion resistance, heat resistance, etc.
- Castability: Molten metal fluidity, solidification characteristics, melt flow, etc.
- Applications: Product areas suitable for each alloy
- Characteristics: Advantages and disadvantages of each alloy
Please comprehensively judge this information and select the optimal alloy.
Selection Examples of Optimal Alloys According to Product Applications, Required Properties, and Usage Environments
The selection of aluminum die casting alloys largely depends on the product’s applications, required properties, and usage environments. Below are specific product examples, the properties required for each, recommended alloys, and the reasons for their selection.
| Product Example | Required Properties | Recommended Alloy | Selection Reasons |
|---|---|---|---|
| Automobile Engine Parts | High strength, heat resistance, wear resistance, castability | ADC12, A380 | Strength retention in high-temperature environments, compatibility with complex shapes due to excellent castability |
| Automobile Wheels | High strength, corrosion resistance, designability, lightweight | ADC3, A356 | Strength during high-speed rotation, corrosion resistance against salt damage, design freedom |
| Automobile Transmission Cases | High strength, wear resistance, vibration absorption, castability | A380, ADC14 | Strength to withstand impacts from gear meshing, vibration absorption characteristics |
| Home Appliance Exterior | Corrosion resistance, designability, lightweight, cost | ADC10, ADC12 | Corrosion resistance to maintain aesthetics, castability to support highly designed shapes, cost suitable for mass production |
| Home Appliance Housings | Strength, rigidity, heat dissipation, lightweight | ADC12, A380 | Strength to protect internal parts, thermal conductivity to efficiently release heat |
| Home Appliance Internal Parts | Precision, dimensional stability, heat resistance | ADC10, ADC3 | Dimensional accuracy to enable precise operation, stability in high-temperature environments |
| Aircraft Parts | High strength, heat resistance, lightweight, reliability | ADC3, A2014 | Strength retention in harsh environments, contribution to aircraft weight reduction |
| Industrial Machinery Parts | High strength, wear resistance, impact resistance | ADC12, A380 | Strength to withstand use under harsh conditions, characteristics resistant to external impacts |
| Industrial Machinery Frames | High rigidity, vibration absorption, weldability | A356, A6061 | Characteristics to increase overall device rigidity, vibration absorption characteristics, joining ability with other members |
| Ship Parts | Corrosion resistance, water resistance, strength | ADC5, ADC6 | Corrosion resistance against seawater, strength to withstand use underwater |
| Motorcycle Parts | High strength, lightweight, wear resistance | ADC12, A380 | Overall vehicle body strength improvement, improved exercise performance due to weight reduction |
| Sports Equipment | Lightweight, strength, durability | ADC10, A356 | Reduced burden during exercise, durability to withstand repeated use |
Supplementary Explanation of Selection Reasons
- Strength: The ability of the product to withstand externally applied forces, such as tensile strength, yield strength, and fatigue strength.
- Heat Resistance: Maintaining strength in high-temperature environments, resistance to deformation.
- Wear Resistance: Resistance to wear due to friction.
- Corrosion Resistance: Resistance to rust and corrosion.
- Castability: Molten metal fluidity, ease of filling molds.
- Lightweight: Improved fuel efficiency and exercise performance due to product weight reduction.
- Dimensional Stability: Small dimensional changes due to temperature changes and aging.
- Weldability: Ease of joining with other members.
- Cost: Comprehensive costs such as material costs, processing costs, and mold costs.
In addition to the above, various required properties need to be considered depending on the product’s application and usage environment. It is important to comprehensively judge these factors in order to select the optimal alloy.
Please consult with a specialist for more detailed information and specific alloy selection examples.
Alloy Selection Considering Cost, Productivity, and Recyclability
In the selection of aluminum die casting alloys, not only product performance but also cost, productivity, and recyclability are important factors. The following explains the points of alloy selection considering these factors.
Material Cost
The price of aluminum die casting alloys varies depending on the type of alloy and market supply and demand. Generally, ADC12 tends to have relatively low material costs because it contains a lot of recycled aluminum. On the other hand, alloys with special properties and alloys containing rare metals may have higher material costs.
Processing Cost
The processing cost of aluminum die-cast products is affected by castability, machinability, surface treatability, etc. Alloys with high castability can efficiently manufacture products with complex shapes, thus reducing processing costs. Alloys with high machinability can reduce the number of secondary processing steps, and alloys with high surface treatability can easily achieve high-quality surface finishes.
Mold Cost
The cost of aluminum die casting molds varies depending on the mold material, shape, accuracy, etc. Alloys with long mold life and easy maintenance can reduce mold costs.
Productivity
The productivity of aluminum die-cast products is evaluated by cycle time and yield. Alloys with short cycle times and high yields can improve productivity.
Recyclability
Aluminum is a highly recyclable metal, and aluminum die-cast products can also be easily recycled. Alloys with high recycling rates and low environmental impact contribute to the realization of a sustainable society.
Optimal Alloy Selection Considering Cost, Productivity, and Recyclability
To select the optimal aluminum die casting alloy, it is necessary to comprehensively consider the above factors. For example, in the case of mass-produced products, ADC12 may be suitable because material costs and productivity are important. On the other hand, in the case of products that require high strength or special properties, alloys such as A380 and ADC3 may be selected even if the material cost is high.
In addition, due to increasing environmental awareness, there is a growing trend to actively utilize highly recyclable alloys and recycled aluminum.
Specific Selection Examples
- Mass-produced automobile parts: ADC12 (excellent material cost, productivity, and recyclability)
- Aircraft parts requiring high strength: A380 (excellent strength and heat resistance)
- Home appliances with complex shapes: ADC12 (excellent castability)
- Products that want to reduce environmental impact: Alloys containing a lot of recycled aluminum
The above are just examples, and the optimal alloy varies depending on the specific requirements of the product.
Other
The selection of aluminum die casting alloys is an important process that greatly affects the quality and performance of products. In order to select the optimal alloy, it is necessary to comprehensively consider various factors such as material properties, product applications, required properties, usage environments, costs, productivity, and recyclability.
Consultation with Experts
To select a more optimal alloy, we recommend that you consult with material manufacturers and experts. Experts can propose the optimal alloy for your needs based on their extensive knowledge and experience. In addition, they are familiar with the latest technical information and market trends, so you can receive more advanced advice.
Collection of Latest Information
Aluminum die casting technology is evolving daily, and new alloys and casting technologies are being developed. Therefore, it is important to constantly collect the latest market trends and technical information and use it for alloy selection.
Points of Information Gathering
- Material manufacturer websites and catalogs: Information on the properties and applications of each alloy, and the latest technical information are posted.
- Expert lectures and seminars: You can learn about the latest technology trends and research results.
- Industry news and technical magazines: The latest information on aluminum die casting is published.
- Exhibitions and trade shows: You can touch actual products and technologies.
Please refer to this information to select the optimal alloy and realize higher quality and higher performance aluminum die-cast products.
Latest Information on Aluminum Die Casting Materials
Aluminum die casting technology is constantly evolving, and various innovative movements can be seen in terms of materials as well. Here, we will introduce the latest trends.
Development Trends of High-Strength Alloys
In recent years, the development of high-strength aluminum die casting alloys is active in order to meet the needs of automobile weight reduction and structural member strength improvement. New alloys with higher strength than conventional alloys are being developed, enabling the manufacture of thinner and lighter products.
Development Trends of Heat-Resistant Alloys
High heat resistance is required for aluminum die-cast products used in high-temperature environments, such as automobile engine parts and aircraft parts. Therefore, the development of new alloys with excellent heat resistance is also progressing. These alloys maintain high strength even at high temperatures and improve product reliability.
Development Trends of Environmentally Friendly Alloys
With increasing environmental awareness, the development of aluminum die casting alloys with low environmental impact is also attracting attention. Alloys that are easy to recycle and alloys that can reduce energy consumption during manufacturing are being developed, contributing to the realization of a sustainable society.
New Casting Technologies
Aluminum die casting technology is also evolving. New casting technologies that can manufacture more precise products and casting technologies suitable for manufacturing thin-walled products are being developed, contributing to product quality improvement and production efficiency improvement.
Standards for Aluminum Die Casting Materials
Standards for aluminum die casting materials include JIS (Japanese Industrial Standards) and ASTM (American Society for Testing and Materials) standards. These standards define material composition and mechanical properties, and play an important role in ensuring product quality.
Latest Research Papers and Technical Information
The latest research papers and technical information on aluminum die casting materials are published in specialized journals and academic conferences. By collecting this information, you can grasp the latest technology trends and research results.
Summary
Aluminum die casting is an efficient casting method that injects molten aluminum alloy into a mold, and material selection affects product quality. Typical alloys include ADC12 (balanced type), ADC10 (high-strength type), ADC3 (high-strength/heat-resistant type), A380 (casting/heat-resistant type), etc. Selection according to product applications (automobile parts, home appliances, aircraft, etc.) and required properties (strength, corrosion resistance, etc.) is important. Consider costs, productivity, and recyclability, and consult with experts, referring to the latest technologies and standards, to select the optimal alloy.
