Aluminum die casting has been around for many years. The practice can be traced all the way back to the 20th century. Die casting today, has been a versatile process for producing engineered metal parts by forcing molten metal under high pressure into steel molds. These molds can then be used to mass produce complex metal alloy components with a variety of surface styles and finishes. Castings are regularly used in many common products in a wide variety of applications: from decorative sculptures, jewelry to automotive and aircraft engine parts.
As time and technology advance, so has the learning curve to produce a variety of the casting and casting finishes’. Product Finishing Magazine has been a great referee for the casting industry, continuously discussing several issues within today’s manufacturing practices. They highlighted some of these regularly accepted loses for the end user: finish too thin, finish is unfavorable (hazy, muddy, not uniform) and/or insufficient corrosion resistance.
To solve these undesired features is to truly understand each step of the metal casting process and critically analyze the die cast substrate variables. Having a working knowledge of the die casting processing tools and machines, pretreatment chemistries’, numerous anodizing bath concentrations and bath temperature effects on different metal alloys; is not a very easy or fast skill to learn and master. The casting Industry expertise is much more complex than this age old process.
Casting and forging metal parts and components has grown into a global market with numerous industry standards and different governmental regulations. Regional standards* of different metal alloys have now been published for casting manufacturers. This lack of uniformity will continue to increase as the industry continues to help grow both developed and under-developed countries compete in this market. For example: copper, magnesium and zinc are among the most important secondary alloying element used in the various casting phases. Controlling and managing these different alloy mixtures gives the final product different strength, corrosion resistance and fatigue resistance.
Gaining this extensive industry knowledge will become increasingly more expensive for companies that require die, sand and investment castings to produce metal components for the aircraft, automotive and other various markets.
There has been a rise in manufacture partners with current casting expertise, leveraging end user companies from receiving less than desired metal parts, metal components that have a higher failure rate and lower quality control measures.
Partnering with Alloy Products Distribution will give you an expert hand in dealing with this very complex manufacturing process. Together we can overcome today’s production barriers, ensuring the demand of a premium casting product is met, helping with inspecting and evaluating the component throughout the forging process and customizing the best practices to produce a finished metal component that is made to your specifications, passed through numerous quality control measures and delivered to your warehouse all before you pay a single dollar!
* Davis, J. R., editor, ASM Specialty Handbook, Aluminum and Aluminum Alloys, ASM International, Materials Park, Ohio, 1993.