1. Identifying the correct alloy to use in your project;
2. Whether or not to use pore-free die casting;
3. If your timetable will allow for the use of cold-chamber machines.
   

Action Steps
The best contacts and resources to help you get it done

Determine the specific diecast aluminum alloy that you need

The Aluminum Association has established the nomenclature for diecast aluminum alloys in the United States. Each alloy series consists of a three-digit number followed by a decimal point. The first digit provides the alloying metal, the second digit gives the percentage of aluminum and the third digit identifies the specific alloy. The number after the decimal point is 0 for casting and 1 for ingots.

I recommend: The Aluminum Association provides indispensable resources for all aluminum part manufacturers and Engineering Fundamentals specifically describes the properties of aluminum alloys by category.

Use the pore-free alloy die casting process

This method of die casting injects pure oxygen into the die before each shot of aluminum. These castings are stronger and can still be welded.

I recommend: Find out about the advantages of pore-free casting at the North American Die Casting Association. Get parts coated with pore-free aluminum by a company such as Alumiplate that specializes in this process.

Use cold-chamber machines for aluminum alloy die casting.

The primary disadvantage of this method is the requirement to transfer the molten aluminum to the cold-chamber machine results in a slower cycle time.

I recommend: Find a variety of new cold-chamber machines at PacMar. Contact Die Cast Press if you need a custom-made die casting machine. Die Cast Press also offers older machines that have been rebuilt.

Helpful advice for making the most of this Guide

• •  The startup cost for aluminum die casting is high. The dies must be made from hardened tool steel because cast iron can't handle the pressures involved.
• •  The high temperature of the molten aluminum contributes significantly to the maintenance cost of die casting. The die itself is subject to wear and erosion and other sources of failure include thermal fatigue and heat checking.