From aluminum die casting vs aluminum extrusion, reader learns about it carefully to help us to handle the aluminum part process and quality control. In fact, we can see two types of common formed aluminum alloy parts, they are die cast aluminum and extruded aluminum parts. Depends on the demand of functions and applications of the parts, various shape aluminum formed parts are processed to meet their utilizations in different fields. The two types of alumium alloy process are different manufacturing processes, which are aluminum die casting and aluminum extrusion.
Aluminum Die Casting Vs Aluminum Extrusion: Features
From the below several aspects, we are known that these two types of aluminum alloy material are significant differences in manufacturing process methods. In feature aluminum die casting vs aluminum extrusion.
| Aspects | Die Cast Aluminum | Extruded Aluminum |
|---|---|---|
| Manufacturing Process | molten aluminum injected into a mold under high pressure. Suitable for high-volume production, and small-to-medium parts | heated solid aluminum extended through a die to form long shapes. Ideal for linear profiles, such as rods, tubes, channels. |
| Strength & Durability | Micro-porosity, reduces strength. Often heat-treated for better properties. | Stronger due to work hardening during extrusion. Better structural integrity. |
| Cost & Production Efficiency | High initial tooling cost, Economic for mass production. | Lower die costs, but post-processing adds expense. More cost-effective for long, uniform shapes. |
| Selection of Aluminum Alloys | ADC12, A380, A356 | 6061, 6063, 7075 |
| Surface Finish Options | As-cast, anodized and painting in common condition | Process, anodized and painting. |
| Precision Tolerancy | High Precision Process, Thin wall is acceptable. | Low tolerancy process, thick wall process. |
| Common Applications | Engine blocks,Electronic housings (laptops, phones),Automotive transmission cases,Power tool bodies,Household appliances | Aluminum frames (windows, doors),Heat sinks,Structural beams ,Pipes & tubing,Automotive rails. |
Aluminum Die Casting Vs Aluminum Extrusion In Parameter
Aluminum Die Casting Parameter
| Aluminum Alloys | Composition | Tensile Strength | Yield Strength | Elongation (%) | Hardness (Brinell HB) |
|---|---|---|---|---|---|
| A380 | Al-8.5%Si-3.5%Cu-0.5%Fe | 315–330 | 160–170 | 2–4 | 80–85 |
| ADC12 | Al-10-12%Si-2.5-3.5%Cu | 300-320 | 150-165 | 1-3 | 75-80 |
| A383 | Al-9.5-11.5%Si-2-3%Cu | 310-325 | 155-170 | 2-4 | 80-85 |
| A360 | Al-9-10%Si-0.4-0.6%Mg | 290-310 | 140-155 | 3-6 | 75-80 |
| A413 | Al-11-13%Si | 280-300 | 130-145 | 2-5 | 70-75 |
Aluminum Extrusion Parameter
| Aluminum Alloys | Composition | Tensile Strength | Yield Strength | Elongation (%) | Hardness (Brinell HB) |
|---|---|---|---|---|---|
| 6061-T6 | Al-1.0%Mg-0.6%Si-0.28%Cu | 310 | 275 | 12 | 95 |
| 6063-T6 | Al-0.7%Mg-0.4%Si | 240 | 215 | 12 | 73 |
| 6005A-T6 | Al-0.5%Mg-0.6%Si | 270 | 240 | 10 | 80 |
| 6082-T6 | Al-1.0%Mg-0.9%Si-0.7%Mn | 310 | 260 | 10 | 95 |
| 7075-T6 | Al-5.6%Zn-2.5%Mg-1.6%Cu | 570 | 505 | 11 | 150 |
Aluminum Die Casting Vs Aluminum Extrusion Process
Aluminum die casting requires to melt aluminum alloy with more heat energy consumption, and through precision steel die, create some intricate design appearance and structural components. While aluminum extrusion allows stamping and ducting the solid aluminum billets into longer dimension and large size simple rails, trims and frames. From the detailed difference from aluminum die casting vs aluminum extrusion.
Aluminum Die Cast Process
- Process Character: Molten aluminum injected into a steel mold under high pressure. Form Complex 3D shapes, thin walls, fine details. remain high precision small and medium sizes casting parts. Especially custom aluminum die casting project.
- Material Properties: Good corrosion resistance, superior heat dissipation, common alloy aluminum, A380, ADC12, A413.
- Cost & Tooling : Intial High tooling cost, economical for high volume production.
- Flexiable Design And High Precision Dimension: The steel die is designed by numberical computer design soft, which design the casting die for cast more intrcate structural parts with tight tolerance dimensions.
- Complex Appearance Design: The precise steel die is micro-processed, especially the cavity of the die, which is engraved, turned, processed by EMD. With the precise die can cast more intricate appearance parts.
Aluminum Extrusion Process
- Process Character: Solid aluminum billet heated and forced through a die. Form intended aluminum parts. Without more heat energy consumption for melting aluminum alloys. extrude some regular rails, frames and simple bodies
- Material Properties: High ductility, strong corrosion resistance and best thermal conductivity. Common aluminum, 6061, 6063, 7075.
- Cost & Tooling: Low die cost, but more post-process is neccessary. Post-process cost is higher.
- Longer production lines: These regular rails are stamped and ducted by heavy industrial equipment, and form some long-dimension large size parts. So longer production lines are needed.
- Applications for Industries: Automotive, Decorative panel and trimming, Window and door frame.
Aluminum Die Casting Vs Aluminum Extrusion In Applications
Applications For Aluminum Die Casting
- Automotive Industry: Engine Components(piston, cylinder head), transmission housing, fuel tube fittings, sensor shieding and security sytem buckles.
- Aerospace and defense: Lightweight structrual components, engine housing and blades and gearbox and cylinder heads.
- Consumer Electronics: Smart phone protective cover, toplap frame, earphone enclosures and connector and shielding components.
- Communication Industry: Connectors, Electrical module bases, thermal-conduct panel and some housings and enclosures for monitoring cameras.
- Industrial And Machinery: These integrated structural die casting components are excellent wear resistance and corrosion resistance.
- Appliance And Homehold Goods: Appliance components, such as main frames, knobs and handles.
Applications For Aluminum Extrusion
- Construction & Architecture: Window and door frames, Curtain walls and structural beams and roofing system.
- Automotive and Transportation: Chassis and frame rail, Radiator supports, Bumper beams and crash structures.
- Heat Sink and Cooling System: Heat sink for electronic and LED lighting, HVAC ducting & heat exchangers.
- Industrial & Machinery: Conveyor system frame, robotic arms and support disks and supporting frames.
- Consumer Furniture: Portable furniture frames and rails, ladder and scaffload, sport goods (bike frame,golf stick).
Conclusion
In summary, aluminum die casting and aluminum extrusion are two main types of of production processes for aluminum components. Different application of aluminum component is decided by aluminum production apporache. We also found that large size aluminum parts can be formed by aluminum extrusion, these parts requires loose dimension tolerance. While the medium and small size parts need tight tolerance for their dimension, they should be cast by precise steel die, belong to aluminum die casting process. Expert suggest that aluminum parts manufacturers should adopt the right process apporache to produce high quality aluminum components.
