Aluminium Die Casting

The entire Aluminium Die Casting process of manufacturing takes place in a well equipped facility with the latest HPDC machined like Buhler , Zitai , Yizumi , Chit-Shun Etc

The largest casting that is presently produced in our facility is about 2.2 Kgs . Our closed loop and real time control die casting machines provide for highly repeatable process with reduced casting rejections and are the most preferred equipment for some of our customers producing safety critical parts for the auto industry.

A Central melting Tower furnace of 500kg/hr capacity along with a couple of BT furnaces of 500Kg capacity provide for molten metal to each of the Electric holding furnaces near the die casting machines.

Post die casting operations like fettling and trimming are carried out by semi-automatic machines. Drilling is carried out a conventional machines using special fixtures to keep costs low.

aluminium-die-casting

surface finishing operations like shot blasting and vibro finishing operations like shot blasting and vibro finishing are carried out in-house along with vacuum impregnation to supply pressure tight castings.

Followed by the Die casting and machining , Some the parts are getting chromating as well as powder coating as per customer requirements.

Using Hot chamber and Cold chamber Die-Cast technologies, along with standard and multi-slide tooling systems. Each of the alloys has unique Chemical and mechanical properties physical to meet out your specific application. We have a team of experts who will assist you to pick the right material to manufacture your complex geometry components.

We are specialized in manufacturing and supplying of Aluminum Casted parts in various  process routes,

  • High-Pressure Die Casting
  • Low-Pressure Die Casting
  • Gravity Die Casting
  • Sand Casting

We make parts from few grams to large precision components in a broad range of

  • Aluminum
  • Zinc

Aluminum Alloy Characteristics

  • High operating temperature

  • Outstanding corrosion resistance properties

  • Lightweight

  • Flexibility in post-process like machining and Surface coating

  • Can cast low wall thickness to reduce the component weight.

  • Very good strength and hardness

  • Good stiffness and strength-to-weight ratio

  • Excellent in Electromagnetic interference (EMI ) shielding properties

  • Excellent thermal conductivity

  • High electrical conductivity

  • Good in surface finishing characteristics

  • Full recyclability

Aluminum’s strength, corrosion resistance, and heat-dissipating properties offer mechanical designers significant advantages. And our proprietary Thin Wall Aluminum Technology has made aluminum die casting an option for even more applications.

Advantages of Aluminum Die Casting

  • Economical process offering a wide range of sizes and shapes

  • One of the most significant benefits of aluminum die casting is that it creates lighter parts—with more surface finishing options than other die cast alloys

  • Cast aluminum is versatile, corrosion-resistant; it retains high dimensional stability

  • Can provide integral fastening elements as part of the design

  • CNC Machining can be used to further refine the design if needed

  • Aluminum Die Cast parts are strong and have a long life span

  • Complex shapes with high dimensional accuracy and stability than other mass production processes

  • Aluminum Die Cast parts can be manufactured with smooth or textured surfaces

  • Aluminum Die Cast parts can be easily anodized, painted or powder coated with minimal surface preparation

Various grade of Aluminum Alloys

High-Pressure Die Casting

A380 , A383 , A413, A360 , ADC1 , ADC 1Z

Low-Pressure Die Casting

A356, A413, AC2A, AC2B, AC4C, AC4A.

Gravity Die Casting

A356, A413, AC2A, AC2B, LM25, AC4A, Al-Si9Cu3.

Squeeze Die Casting

A380, A383.

Sand Casting

A356, A413, AC46200, AC2A.

Zinc

Zamak3, Zamak5, Zamak7

Magnesium

AZ91D, AM50A, AM60A

High Pressure Die Casting

  • We make HPDC components range from 25 Grams to 20 Kgs. We equipped machine range from 80 Ton to 3400 Ton Precision High pressure Die Casting Machines.

  • Most of the machines having a closed-loop operation, Automatic spray, Auto ladle, Auto extractor capabilities, where we can make the high precision and varied wall thickness parts with the desired quality level.

  • Every HPDC machine having to hold a furnace, where we can control the temperature and alloy properties very precisely.

high-pressure-die-casting-1

Low Pressure Die Casting

Low-pressure die casting is a method of production that uses pressure – rather than gravity – to fill molds with molten metal such as aluminum and magnesium. In this process, the holding furnace is located below the cast and the liquid metal is forced upwards through a riser tube and into the cavity

Gravity Die Casting

  • Our Gravity Die Casting capabilities includes Stationary and Tilting type GDC machines

  • We make GDC components range from 100 Grams to 100 Kgs.

  • We have the equipment to make the Shell Core for the comply casting profiles.

  • Followed by the GDC process, We perform Solution Heat Treatment & Precipitation Heat Treatment to achieve the mechanical properties

gravity-die-casting-1

Sand Casting

  • We make Alu casting through the NO BAKE Sand casting process, where we produce parts from 10 Grams to 250 Kgs Kgs.

Extrusion

  • Extrusion is the process used to create lengths of aluminum of a fixed cross-sectional profile.

  • The process of aluminum extrusion works by forcing a block of metal, known as a billet, to pass through the die opening of the smaller cross-sectional area than the billet itself

  • Aluminum extrusion is a process for creating parts with specific cross-sectional profiles by pushing heated alloy material through a die.

  • Shapes created can be solid, hollow, and semi-hollow; and they can be simple or they can be complex.

  • The process of extrusion is an interesting one, resulting in 8-24 foot long profiles that can then be heat treated, finished, and fabricated to customer specifications.

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IS India(NEW) (BS)U.K or I.S.(OLD) (AA)
U.S.A		 (AICAN)
Canada		 DIN
Dermany		 ASTM (JIS)
Japan		 (AFNOR)
France		 Russia
19500 E1B 1050 or.1060 IS AI 99.5 99.6A AI-1 A-5 –
19000 E1C 1100 2S AI 99.0 99.0A AI-3 A-4 A-2
19501 E1E EC CISDIA E-AI99.5 EC AI-1 – –
63401 E91E 6101 D50S E-AI-Mg.Si.O.5 GS 10B – – –
– NE-3 3103 3S AI Mn – – 3103 –
52000 NE-4 5052 M57S AIMg2 GR 20A A2-SI A-G3 AM
53000 NE5 5086 54S AiMg3.5 GM 40A – – –
63400 HE-9 6063 50S AiMg Si0.5 GS 10A A2-S5 A-SG> –
24345 HE-15 2014 B26S AI-Cu-Si – – – –

Temper Designation Table

INDIA or U.K U.S.A or CANADA ISO TEMPER Description of designation
O O O Annealed
M F F As fabricated, as manufactured, or as cast
– T3 TD Solution heat-treated and cold worked
W T4 TB Solution heat-treated, naturally aged, and amenable to artificial ageing
P T5 TE Artifically aged or precipitation heat-treated
WP T6 Tf Solution heat-treated & Precipitation heat-treated
H-21  H-1 H2A H1 Strain hardened to the specified strength
H-22 H-32 H2B H3B 1/4 Harf Stabilized
H-24 H-34 H2D H3D 1/2 Harf Stabilized
H-26 H-36 H2F H3F 3/4 Harf Stabilized
H-28 H-38 H2H H3H Fully hard, stabilized