Die Casting with Aluminum – Versatility Meets High Performance

Die Casting with Aluminum – Versatility Meets High Performance

Aluminum castings are lightweight, possess good physical properties, high dimensional stability, high electrical conductivity, and are able to withstand high operating temperatures. Since aluminum also resists corrosion and can be easily cast. The majority of all die castings produced all over the world are made from aluminum alloys.

Aluminum is a very versatile material and is used for many applications; giving mechanical designers significant advantages when creating lightweight parts that withstand high temperatures. Aluminum die casting is often used in the defense and medical industries as a light and durable alternative to other metals while retaining maximum stability. It is also an exceptional thermal conductor for heat dissipation while maintaining rigidity and resilience when used for EMI/RFI shielding in the telecom and electronics industries.

Why choose aluminum?
• Lightweight
• High dimensional stability
• Corrosion resistance
• Excellent mechanical properties
• Good machining characteristics
• Superior EMI and RFI shielding properties
• High thermal and electrical conductivity
• High strength-to-weight ratio
• A variety of decorative and protective finishes
• Great choice for high temperature coating processes
• Made from 100% recycled material and is fully recyclable

With strength comparable to zinc alloys, aluminum is frequently chosen when weight is at a premium. One of the most significant benefits of using aluminum is that it has a very low specific gravity which places it amongst the most lightweight structural materials available today.

What are some typical applications for aluminum?
• Since aluminum castings are resistant to corrosion they are often used in marine grade applications.
• Aluminum is great for dissipating heat and is used in a broad range of networking and infrastructure equipment in the telecom and computing industries.
• Aluminum castings provide EMI/RFI shielding, rigidity, and durability.
• Die cast aluminum is ideal for electronic connectors and housings because aluminum has excellent electrical performance and shielding properties, even in high-temperature environments.

The best part?
With our strong commitment to protecting the environment, A&B uses only 100% recycled materials. The ease of use in die casting combined with lighter weight and durability make aluminum a top choice for designers from nearly any industry.

Want more in-depth information?
Click here to download a PDF that goes into some very good detail about aluminum alloys from NADCA’s product specification and standards for die casting.

Ready to get started?
Contact A&B Die Casting about your next project today!
(877) 708-0009
www.abdiecasting.com

K-Alloy is A-OK for A&B Customers

K-Alloy is A-OK for A&B Customers

A304 (K-Alloy) was developed by Delphi in 2003 as an innovative aluminum die casting alloy that resists corrosion, but until a few years ago was only available from a smelter on the east coast. A&B Die Casting is delighted to announce that our west coast supplier is now a licensed source of K-Alloy, making access to the alloy simpler and recycling of the alloy more efficient.

K-Alloy/A304 has been tested to withstand 3,000 hours of salt spray testing with no metal loss or surface damage. Other aluminum alloys would require additional processes and/or coatings to withstand this harsh environment.

The rugged durability of K-Alloy can eliminate expensive processes such as anodizing, chromating, powder coating and painting that are designed to slow corrosion. In addition to cosmetic improvements, K-Alloy applications provide increased functional durability for aluminum cast components in harsh environments.

Originally developed to withstand extreme salt corrosion and temperatures, vibration, and shock experienced in vehicle engine electronics, K-Alloy aluminum is currently being used or being tested on products as diverse as fishing reels, outdoor lighting, furniture, water fountains, mail boxes, radios and vehicle roof racks.

Not All Alloys Are Created Equal

Not All Alloys Are Created Equal

Alloy composition is just one part of the equation for quality parts.

All alloys have unique physical characteristics to match specific engineering applications. The alloy affects the structural strength of a casting, the skin versus the core of the casting, and the ability to control the process to make the best use of the material.

While it is important to examine the composition of different alloys, it is just as important to ensure the purity of that composition.

Contamination of an alloy can easily result from two common practices:
• Re-melting metal that has already been through the casting process, such as scrap or defective parts.
• Re-melting runners or overflows from the casting process.

Over time, the gradual erosion of tooling can introduce traces of elements such as iron into the casting. These trace elements can slowly creep above acceptable ranges of a specified alloy when they are added back into the melt. Although higher levels of Iron (Fe) can help the die casting process by reducing sticking of the part in the tooling, it can produce an alloy that is out of spec over time if not managed well.

To eliminate the risk of contamination, A&B Die Casting never re-melts runners or overflows from our castings.
• A&B Die Casting sends all runners and overflows to our outside suppliers for recycling and requalifying of the alloy.
• A&B sources all our metal from top-quality suppliers Custom Alloy Light Metals and CASS located in the United States.
• A&B tooling uses premium H-13 that exceeds NADCA 207-2003 Superior Specification or better to resist erosion.

A&B Die Casting ensures the material our customers’ order is the material we pour for our castings.