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2020.12.22
The majority of die castings are made from aluminum alloys, there are lots of different alloys used for aluminum die casting. Here we’ll start with what is die cast aluminum, then go through the common aluminum die casting alloys including A380, A360, 383, etc., and their composition, properties, to find the best aluminum alloy for die casting.
Die cast aluminum is a type of aluminum that is melted to a liquid and forced into the mold cavities under high pressure and then hardens to the desired shape, for producing the final die casting aluminum parts. Aluminum die casting uses the non-expendable mold to produce metal castings repeatedly, the die cast aluminum can be fabricated to different dimensions and shapes for a variety of industries, aluminum castings with great accuracy and properties are commonly used in the automotive industry.
Die cast aluminum alloy mainly consists of silicon, copper, magnesium, iron, manganese, and zinc. Each element has a different impact on the properties of the alloy. When working with aluminum, you need to choose which type of aluminum alloy to use in the die casting services. Looking at the following die casting aluminum alloys to find the best one for yourself.
Aluminum Alloy A360 (ANSI/AA A360.0): high corrosion resistance, superior strength at elevated temperatures and good ductility, excellent pressure tightness, and high fluidity, but relatively difficult to cast.
Aluminum Alloy A380 (ANSI/AA A380.0): the most common die cast aluminum, it offers both great properties and ease of production, this alloy exhibits excellent fluidity, light weight, resistance to corrosion and hot cracking, pressure tightness, dimensional stability, high strength at high temperatures and high electrical conductivity, widely used in tools, frames, electronics, communications equipment, automotive engine, and other parts, transmission and gear cases, furniture, appliances, and more industries. Alloy A380 also has better than average machining characteristics.
Aluminum Alloy 383 (ANSI/AA 383.0): can be used as the alternative of A380 for intricate components, it has good mechanical properties and improved die casting properties.
When it comes to the selection of the best aluminum alloy for die casting, other die casting aluminum alloys including AA C443.0, AA A413.0, AA B390.0, AA 518.0, and more. The most popular alloy for aluminum die casting is A380, you can use A383 when producing intricate die casting components that requiring specific die-filling performance, but the castings made from A383 is not as durable as A380. A360 is more difficult to cast than A380, you can check its properties below when considering using it.
Density: About 2.7 g/cm3, which is roughly one-third the density of steel. This makes it a lightweight yet strong material.
Tensile Strength: 200-350 MPa for common alloys like A380, A360, depending on specific composition and heat treatment. Slightly lower than mild steel but still robust.
Hardness: Range from 30-150 HB depending on alloy and process. Commonly 75-90 HB for general purpose alloys. Heat treatments improve hardness.
Corrosion Resistance: Exhibits excellent corrosion resistance due to a thin, tough oxide layer that forms on the surface and protects the metal. Good for outdoor applications.
Ductility: Typically 5-15% elongation is possible. Certain alloys can achieve 20-30% elongation. More rigid than steels but still has some flexibility.
Heat Conductivity: Significantly lower than steel at around 100-180 W/mK. Good for applications needing heat resistance.
Machinability: More difficult to machine than steel but finishes provide a smooth surface. Machining leaves swarf that needs extraction.
Dimensions: Die casting allows dimensions to be held within a few thousandths of an inch, with complex internal passages.
Cost: Generally cheaper than machining other metals into comparable components. Rapid production process.
Here are two comparison tables of aluminum alloy die casting, the first one indicates the chemical composition of different aluminum die cast alloys. The single values listed below refer to the maximum composition percentages. And in the second comparison chart, you can find varying mechanical and physical properties of common cast aluminum alloys.
