Aluminum die casting forces molten aluminum into mold cavities under high pressure. You generally make aluminum die castings from alloys rather than pure aluminum because of its tendency to crack.

Aluminum die casting creates many small- to- medium-sized parts that are all the same and have fine detail. Before proceeding with an aluminum die casting job, be aware of some basic issues, and decide whether you will be purchasing aluminum die casting machinery for your shop, or whether you will be using the services of an aluminum die casting company.

Before making a decision on aluminum die casting, consider these options:

1. Find an aluminum pressure die casting manufacturer with a long-standing reputation for excellence, if you are outsourcing.

2. Use a distributor of foreign-made aluminum die castings to save money.

3. Look for aluminum die casting machinery that can achieve precise tolerances, if you are buying one to use in-house.

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

Do business with an experienced aluminum die casting company

The longer a company has been in business, the more time it has had to gain a good reputation, grow and become more innovative. The fact that an aluminum die casting company has a history of satisfied customers going back many decades indicates the company can be trusted to provide quality products and services.

I recommend: Walker Die Casting has been making aluminum die castings since 1958. Its large staff has extensive experience, with employees averaging more than 10 years apiece in the industry. Cast Well, in business since 1946, guarantees quality assurance to military and ISO standards and uses several quality control methods.

Purchase your aluminum die casting through a distributor to save money

Aluminum die casting distributors who work with foreign manufacturers can help you save quite a bit of money by having die castings custom-engineered for you overseas.

I recommend: Material Technology Solutions, a multinational distributor, has a program to supply North American service centers with all their aluminum needs, including aluminum alloy die casting. Samco Sales, Inc. offers aluminum alloy die castings made inexpensively in China.

Buy aluminum die casting machinery for in-house aluminum die casting

An aluminum alloy die casting should have uniform wall thicknesses and cores of simple shapes so parts of the cast aren't weak. The aluminum die casting process requires castings to have a draft allowance of 0.25 to 0.75 degrees per side so they can come out of the mold easily. If you're looking for an aluminum die casting machine, make sure it fits these standards.

I recommend: New Vista Corporation's new automated trim and degate machine, the TAD 1000, offers maximum efficiency to the die casting industry. Ray Jacobs Machinery Co. specializes in used machinery for metallurgy, including used die casting aluminum machines.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  If you have colleagues in your industry who have used aluminum die casting services, ask them for recommendations.