Aluminum Diecasting or Die Castings Technical Information Page 1 of 5

Technical Information about Die Casting

Die Casting, A Description of the Die Casting Process - Die casting is a
manufacturing process in which molten metal is injected, under considerable pressure,
into a hardened steel die or also called die casting mold. Dies are often water-cooled.
The die is then opened, and the die casting parts are ejected (many times thousands of
die casting parts each day, sometimes only a few hundred die casting parts). Once the
die casting tooling is paid for, die casting parts are a very inexpensive aluminum part
manufacturing process.
Contact or Request Prices

Technical Information about Die Casting Aluminum Alloys

Chemical Breakdown of Die Cast Aluminum Alloys
Compare Other Die Casting Materials to Aluminum
Compare Die Casting to Other Manufacturing Processes

Aluminum Die Casting Alloy Metals: A360 Aluminum Alloy.

A380 Aluminum Alloy.
A383 Aluminum Alloy.
A413 Aluminum Alloy.
Size Range: Not normally over 2 feet square.

Part Weights: .001 pounds to 10 pounds.

Parts comply with the EU RoHS standards

Setup Cost: New tooling setup is free with free first article report.

Tolerances:
 Aluminum die cast parts ± .002"/in.
 Add ± .001" to ±.015" across parting line depending on size.

Surface Finish: 32-63RMS.

Minimum Draft Requirements: Aluminum 1° to 3°.

Normal Minimum Section Thickness:

 Aluminum die cast parts: 0.060" small parts, 0.090" medium parts.

Ordering Quantities: Sometimes less than 100 parts, but usually 1,000 parts or more.

Normal Lead Time:

 Tooling: Sometimes as little as 4 weeks or as much as 12 weeks.

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 Samples: Usually the week the die is available.

 Production: Starts usually within two weeks (sometimes less) after approval.

Technical Information
about
Die Casting Aluminum Alloys
The following table will provide a general idea of the differences in Aluminum Die Cast
alloys. Kinetic Die Casting will help you any technical information. A little information
about Kinetic Die Casting Company can be found on our profile page.

ALUMINUM ALLOY CHARACTORISTICS

Aluminum die casting alloys A360 A380 A383 A413
Hardness 75 80 75 80
Elongation (% in.2 in.) 2.5 3.5 3.5 2.5
Shear Strength (ksi) 28 28 - 25
Tensile Yield Strength (ksi) 25 23 22 21
Ultimate Tensile Strength (ksi) 44 46 45 43
Thermal Conductivity 65 56 56 70
Electrical Conductivity (% copper) 30 27 23 31
Density (weight) Lbs./ in.3 0.095 0.099 0.099 0.096

ALUMINUM ALLOY ADVANTAGES

Aluminum die casting alloys A360 A380 A383 A413
(1= most desirable, 5= least desirable):
Pressure Tightness 2 2 2 1
Die Filling Capacity 3 2 1 1
Anti-Soldering to Die 2 1 2 1
Corrosion Resistance 2 4 3 2
Machining ease & quality 3 3 2 4
Strength at high temperatures 1 3 2 3
Material cost 3 1 2 4

ALUMINUM ALLOY MATERIALS

Aluminum die casting alloys A360 A380 A383 A413
Silicon (Si) 9.0-10.0 7.5-9.5 9.5-11.5 11.0-13.0
Iron (Fe) 2.0 2.0 1.3 2.0
Copper (Cu) 0.6 3.0-4.0 2.0-3.0 1.0
Manganese (Mn) 0.35 0.50 0.50 0.35
Magnesium (Mg) 0.4-0.6 0.10 0.10 0.10
Nickle (Ni) 0.50 0.50 0.30 0.50
Zinc (Zn) 0.50 3.0 3.0 0.50

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Tin (Sn) 0.15 0.35 0.15 0.15

Others 0.25 0.50 0.50 0.25
Aluminum (Al) Balance Balance Balance Balance

Aluminum Die Cast Parts comply with the EU RoHS standards

Other Die Casting Alloy Materials Comparison

Aluminum Brass Magnesium Zinc
Tensile strength, psi x 1000 47 55 34 41
Yield strength, psi x 100 (0.2 pct
23 30 23 —
offset)
Shear strength, psi x 1000 28 37 20 31
Fatigue strength, psi x 1000 20 25 14 7
Elongation, pct in 2 in. 3.50 15 3.0 10
Hardness (Brinell) 80 91 63 82
Specific gravity 2.71 8.30 1.80 6.60
Weight, lb/cu. in. 0.098 0.305 0.066 0.24
Melting point (liquid), °F 1100 1670 1105 728
Thermal conductivity, CG5 0.23 0.21 0.16 0.27
Thermal expansion, in./in./°F x
12.1 12.0 15.0 15.2
106
Electrical conductivity,
27 20 10 27
pct of copper standard
Modulus of elasticity, psi x 106 10.3 15 6.5 —
Impact strength (Charpy), ft/lb 3.0 40 2.0 43.0

Cast-Parts

We are a Corporate Member of NADCA (North American Die Casters Association).

NADCA helps manufacturers (OEM's and Die Casters) with information concerning die
casting of all types and materials. NADCA also publishes specifications for die cast
parts.

North American Diecasters Association

Compare High pressure die casting to Other Manufacturing Processes

Why Use Die Casting in aluminum:

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Forgings
Compared with forgings, die casting can be more complex in shape and have shapes not
forgeable, can have thinner sections, be held to closer dimensions, and have coring not
feasible in forging.

Plastic Injection moldings

Compared with plastic injection moldings, die casting are stronger, stiffer, more stable
dimensionally, more heat resistant, and are far superior to plastics on a properties/coat
basis. They help prevent radio frequency and electromagnetic emissions. For chrome
plating, die castings are much superior to plastics. Die castings have a high degree
permanence under load compared to plastics, are completely resistant to ultra-violet
rays, weathering, and stress-cracking in the presence of various reagents. Manufacturing
cycles for producing die castings are much faster than for injection moldings.

Extrusions
Compared to extrusions, die casting can be produced faster and more net shape. Features
and depressions on the sides, tops and bottoms can be created in one operation. There is
less waste using die casting than extrusion. Holes can be cast in place to save additional
machining cost.

Stampings
Compared with stampings, one die casting can often replace several parts. Die casting
frequently require fewer assembly operations, can be held within closer dimensional
limits, can have almost any desired variation in section thickness, involve less waste in
scrap, and are producible in more complex shapes. Die castings can be made in many
shapes not producible in stamped form.

Screw Machine Parts

Compared with screw machine products, die castings are produced more rapidly, involve
much less waste in scrap, can be made into shapes that are difficult or impossible to
produce from bar or tubular stock, and may require fewer operations.

Sand castings
Compared with sand castings, die castings require much less machining, can be made
with thinner walls, can have all or nearly all holes cored to size, can be held within much
closer dimensional limits, and are produced more rapidly in dies which make thousands
of die castings without replacement. Die castings do not require new cores for each
casting, are easily provided with inserts die cast in place, have smoother surfaces and
involve much less labor cost per casting.

Permanent mold castings

Compared with permanent mold castings, die castings can be made to closer
dimensional limits and with thinner sections and holes can be cored to near net shape.
Die castings are produced at higher rates with less manual labor, have smoother
surfaces, and usually cost less per die casting.

Glossary of Die Casting Terms

Aluminum Die Cast Parts - End result of our efforts.

Die Casting Processes

Tooling Die Casting. Die Casting Draft Angle. Alloys for Die Casting. Aluminum Die
Casting Company. Zinc Die Casting Company. Magnesium Die Casting Company.
Porosity in Die Castings. Sand Castings. Technical Die Casting Terms. Die Castings

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Compared to Steel. Die Castings Compared to Plastic. Capabilities of Die Casting. Why
use Diecasting. What is Die Casting. American Die Casting Company . Manufacturing
Die Castings . Custom Metal Parts. Diecast Quality Production. Die Casting Aluminum.
Diecasting Company. Kinetic Die Casting Company.

Kinetic Die Casting, Inc.

6918 Beck Avenue, North Hollywood, CA 91605
Toll Free: (800) 524-8083 Local: (818) 982-9200 Fax: (818) 982-0877
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