Aluminum Die Casting
High-pressure die casting with ADC12 and A380 alloys. Ideal for complex, thin-wall, high-volume parts with consistent repeatability.
When Die Casting Is the Right Choice
High-pressure die casting injects molten aluminum into steel dies at 10–175 MPa. The fast fill and solidification cycle (seconds per part) makes it the most efficient process for high-volume production of complex, thin-wall components.
Die casting excels at producing near-net-shape parts with excellent surface finish and tight dimensional tolerances — minimizing post-machining requirements.
⚠️ Note: Die cast alloys (ADC12, A380) are generally NOT heat treatable to T6. For structural parts requiring high strength and ductility, consider our gravity casting or low-pressure casting processes with A356/ZL114.
- Fastest cycle times — seconds per part
- Excellent for thin walls (≥ 1.5 mm)
- High surface quality, low post-machining
- Complex geometry possible
- Best for volumes > 5,000 pcs/year
Process Specifications
How Aluminum Die Casting Works: Step-by-Step
Understanding the die casting process helps procurement teams write better RFQs and evaluate supplier capabilities accurately. Here is what happens from raw material to finished part.
1. Die Preparation
Steel dies are preheated and coated with a release agent. Two die halves — the cover die (fixed) and ejector die (moving) — are clamped together by the machine at 400–4,000 tonnes of locking force.
2. Injection
Molten aluminum at 650–710 °C is injected into the die cavity at high speed (30–100 m/s gate velocity) and high pressure (10–175 MPa). The cavity fills in milliseconds, capturing fine details and thin walls down to 1.5 mm.
3. Solidification & Cooling
The alloy solidifies rapidly in the water-cooled steel die. Intensification pressure is maintained during solidification to reduce shrinkage porosity. Cycle time ranges from 15–90 seconds depending on part size.
4. Ejection & Trimming
The die opens, ejector pins push the casting out, and the shot, runners, and overflows are trimmed. Parts proceed to deburring, machining, and surface treatment as required.
Die Casting vs Gravity Casting vs Low-Pressure Casting
Choosing the right casting process depends on your part's geometry, volume, mechanical requirements, and budget. Here is how the three main aluminum casting routes compare.
| Feature | Die Casting (HPDC) | Gravity Casting | Low-Pressure Casting |
|---|---|---|---|
| Pressure | 10–175 MPa | Gravity only | 0.03–0.1 MPa |
| Min Wall Thickness | 1.5 mm | 3–4 mm | 3 mm |
| Typical Alloys | ADC12, A380 | A356, ZL114 | A356 |
| Heat Treatable (T6) | No | Yes | Yes |
| Surface Finish | Ra 1.6–3.2 µm | Ra 3.2–6.3 µm | Ra 3.2–6.3 µm |
| Tooling Cost | $15K–$80K | $5K–$30K | $8K–$40K |
| Ideal Volume | > 5,000/year | 500–50,000/year | 1,000–30,000/year |
| Cycle Time | 15–90 sec | 3–8 min | 2–6 min |
| Porosity Risk | Higher (gas entrapment) | Lower | Lowest |
| Best For | Complex thin-wall, high volume | Structural, heat-treatable | Symmetrical, low-porosity |
Not sure which process fits your part? Send us your drawing and our engineers will recommend the best route.
Die Casting Alloys: ADC12 vs A380
The two dominant die casting alloys serve slightly different needs. ADC12 (JIS standard, also known as A383 in ASTM) offers excellent castability and corrosion resistance. A380 provides a good balance of mechanical properties and cost.
ADC12 (A383)
- • Tensile strength: 310 MPa
- • Yield strength: 150 MPa
- • Elongation: 3.5%
- • Si content: 9.6–12.0%
- • Best for: Housings, brackets, enclosures, automotive electronics covers
- • Advantage: Superior die filling, lower hot cracking tendency, better pressure tightness
A380
- • Tensile strength: 324 MPa
- • Yield strength: 159 MPa
- • Elongation: 3.5%
- • Si content: 7.5–9.5%
- • Best for: Engine brackets, gear cases, furniture fittings, hand tools
- • Advantage: Most widely used die casting alloy globally, excellent machinability
Typical Die Casting Applications
Automotive
Transmission housings, engine brackets, sensor covers, EV battery enclosures, steering column housings, throttle bodies
Learn more →Industrial Equipment
Pump covers, motor housings, pneumatic valve bodies, gearbox casings, hydraulic manifolds
Learn more →Consumer Electronics
Heat sinks, laptop chassis, LED lighting housings, 5G antenna brackets, camera bodies
Home Appliances
Washing machine brackets, refrigerator compressor parts, power tool housings, coffee machine components
Learn more →Energy & Power
Solar inverter housings, wind turbine brackets, transformer casings, switchgear enclosures
Learn more →Telecom Infrastructure
5G base station heat sinks, fiber optic junction housings, antenna mounts, server rack components
Die Casting Design Guidelines for Buyers
Following these design principles helps reduce tooling cost, improve part quality, and shorten lead times. Share these with your engineering team before sending an RFQ.
Uniform Wall Thickness
Maintain consistent wall thickness (1.5–4 mm recommended) to minimize shrinkage porosity and warping. Gradual transitions are better than abrupt changes.
Draft Angles
Apply 1–3° draft on all surfaces parallel to die opening direction. Internal surfaces need slightly more draft than external ones.
Fillet Radii
Use generous fillets (R ≥ 1 mm) at all internal corners. Sharp corners create stress concentrations and can cause premature die wear.
Undercuts & Slides
Avoid undercuts where possible. Each undercut requires a side-action slide, increasing tooling cost by $2,000–$8,000 per slide.
Ribs for Strength
Use ribs instead of thicker walls to add stiffness. Rib thickness should be 50–70% of the adjoining wall to avoid sink marks.
Boss Design
Bosses for screws or inserts should have a wall thickness of 60% of the nominal wall, with fillets at the base.
Frequently Asked Questions About Die Casting
What is aluminum die casting?
Aluminum die casting is a manufacturing process where molten aluminum is injected into a hardened steel mold under high pressure (1,000-1,500 bar). It produces complex, thin-wall parts with excellent dimensional accuracy and surface finish at high production speeds.
What alloys are used in die casting?
The most common die casting alloys are ADC12 (A383) and A380. These eutectic aluminum-silicon alloys offer excellent fluidity for filling thin sections, good mechanical properties, and fast cycle times. They are not typically heat treatable.
What is the minimum wall thickness for die casting?
Aluminum die casting can achieve wall thicknesses as thin as 1.0-1.5mm, which is significantly thinner than gravity casting (3-4mm minimum). This makes die casting ideal for lightweight, complex enclosures and housings.
How much does die casting tooling cost?
Die casting tooling typically costs $15,000–$80,000 depending on part complexity, number of cavities, and die steel grade (H13 is standard). Tooling lead time is 60–90 days. For large automotive programs, multi-cavity dies can exceed $100,000 but dramatically lower per-part cost.
What is the typical lead time for die casting production?
Once tooling is approved, sample production takes 1–2 weeks. Mass production lead time is typically 4–6 weeks for an initial order, with subsequent orders shipping in 2–3 weeks depending on volume and finishing requirements.
Can die cast parts be anodized?
Standard die cast alloys (ADC12, A380) have high silicon content that produces a dark, non-uniform anodized finish. If a cosmetic anodized finish is critical, consider gravity-cast A356. Die cast parts can be powder coated, painted, chromate converted, or nickel plated for surface protection.
What is the difference between hot chamber and cold chamber die casting?
Aluminum uses cold chamber die casting — the molten metal is ladled into a shot sleeve before injection. Hot chamber machines (used for zinc and magnesium) keep the injection mechanism submerged in the melt. Cold chamber is necessary because molten aluminum would attack hot chamber components.
How do I reduce porosity in die castings?
Key strategies include optimizing gate design and venting, using vacuum-assisted die casting, controlling metal temperature (660–710°C), maintaining proper intensification pressure, and ensuring consistent die temperature through cooling channels. Design-wise, avoid thick sections and ensure uniform wall thickness.
Is die casting suitable for structural automotive parts?
Standard HPDC has porosity risks that limit structural use. However, vacuum die casting and squeeze casting variants can produce structural components. For safety-critical parts requiring T6 heat treatment and high elongation (>7%), gravity casting with A356/ZL114 is usually preferred.
Related Resources
ADC12 vs A356: Which Alloy Is Right for Your Part?
Compare the two most common aluminum casting alloys for automotive and industrial applications.
Aluminum Casting Defects: Causes & Prevention
Understand common casting defects like porosity, cold shuts, and misruns — and how to prevent them.
How to Choose an Aluminum Casting Supplier in China
A practical framework for evaluating foundries based on certifications, capability, and communication.
High-Volume Die Casting?
Share your part drawing and annual volume. We'll assess and quote within 24 hours.
Request a Quote