titanium vs aluminum

Are you on the cross as to whether you should use titanium or aluminum alloy for your project? Don’t worry; it is not a unique occurrence to you because many engineers and designers are in the same boat. These metals are quite similar and used interchangeably but also distinct in their characteristics, and knowing how those characteristics can affect performance, expense, and adaptability is critical. The inability to make the right decision may result in time wastage and additional expenses on the project.

The major areas of disparity between titanium and aluminum include strength-to-weight ratios, corrosion, and thermal characteristics. Titanium is more resistant to corrosion and is stronger than aluminum most of the time, thus making it perfect for use in hard working environments or areas that require its strength while aluminum is lighter, cheaper, and perfectly fit for normal use. Finally, the decision comes to certain parameters like weight and conditions in which the equipment will be used.

As you now have a general understanding of how titanium and aluminum differ let us look at the individual characteristics and uses for each metal. By looking at these factors, you’ll be able to make a better decision that fits your project. So, read on to find out which material will fit you best.

titanium material

Titanium vs Aluminum: Comparing Their Properties

Such a comparison could be incomplete if the various properties of each material affect their performance as different applications are not taken into consideration. Titanium also has a higher strength-to-weight ratio than steel, so not only is it strong, it is light. It also has excellent corrosion resistance, especially in severe conditions it is used for aerospace, medical implants, and marine. In contrast, aluminum itself to a lightweight material, easy to machine, and relatively cheaper than copper. This is used in automotive applications, construction, and consumer products because of its versatility and ease of fabrication.

Mechanical Properties

Perhaps the most important of these is the mechanical properties comparison between titanium and aluminum. TiAl has an ultimate tensile strength of approximately 434 MPa to 1400 MPa based on the type of alloying used in its production whereas aluminum has an ultimate tensile strength of about 90MPa to 700 MPa. This tells you that titanium can take much stress before it fails, therefore it should ideally be used where high strength is needed. Concerning the elongation, titanium is less ductile than aluminum which makes it easier for the aluminum to deform without fracture hence more freedom in design.

Weight Considerations

Another important consideration in choosing between these metals is weight. Aluminum is much lighter than titanium, with a density of 2.7 g/cm³ in comparison with 4.5 g/cm³ for titanium. This lower density makes aluminum widely used in industries where weight has to be cut down for example in the manufacture of aircraft and cars. However, high strength requirements together with weight savings give titanium the better of it even if it is heavier than the other materials.

Corrosion Resistance

They both have fairly good corrosion resistance characteristics, although the resistance is in different media. It stated that titanium corrosion resistance is excellent in severe service environments, especially when it is exposed to chlorine or salt water, and having a dense oxide layer on the material surface Prevents further corrosion. Aluminum also forms an oxide layer, but it is vulnerable to pitting attack in some specific conditions; for example, it reacts with seawater or hot alkali. Therefore, titanium finds its application in marine and chemical processing industries.

Titanium

Thermal Conductivity and Conductivity

The thermal coefficient should also be taken into account when selecting titanium aluminum alloy. Specifically, the thermal conductivity of aluminum is listed at about 205 W/mK, whereas that of titanium is about 21.9 W/mK. This makes aluminum more conductive of heat in applications such as heat exchangers and cooling systems. Having lower heat conductivity though is also beneficial in places where heat is not required such as in spaces used for the construction of aircraft among others.

Cost and Availability

Cost is one of the most important considerations when choosing the material to use in construction. Aluminum under most conditions is likely to be more available and cheaper than titanium and hence can be more suitable for several uses. Aluminum manufacturing processes are also very well defined and often the overall process is less complex and therefore cheaper. On the other hand, extraction and processing of titanium are expensive and difficult, thus its application is restricted to areas where its properties offer great value.

Summary of Applications

Therefore, there is a direct comparison between Titanium and Aluminum and it depends on the nature of the project that has to be done. Titanium has been considered in aerospace, biomedical, and marine industries where high strength and superior corrosion resistance properties are critical. Aluminum is extensively used in automobile, construction, and other consumer goods industries because of its lightweight, low cost, and ease of workability. Knowledge of these properties can assist engineers and designers in making correct decisions by the objectives of the particular project.

titanium vs. aluminum

Here are properties chart comparing titanium and aluminum, followed by a technical brief summarizing the key differences.

PropertyTitaniumAluminum
Density4.5 g/cm³2.7 g/cm³
Tensile Strength434 – 1,400 MPa90 – 700 MPa
Yield Strength880 – 1,200 MPa40 – 550 MPa
Elongation10 – 30% (varies by alloy)12 – 25% (varies by alloy)
Corrosion ResistanceExcellent (especially in saline and harsh environments)Good (but susceptible to pitting)
Thermal Conductivity21.9 W/mK205 W/mK
Electrical Conductivity2.0 x 10^6 S/m3.5 x 10^7 S/m
Melting Point1,668 °C660 °C
Modulus of Elasticity110 – 120 GPa70 – 80 GPa
CostHigh (more expensive to extract and process)Lower (abundant and cost-effective)
MachinabilityDifficult (requires specialized tools)Good (easier to machine and fabricate)
ApplicationsAerospace, medical implants, marine, automotiveAutomotive, construction, consumer goods

Introduction to Aluminum

Aluminum is light in weight, strong, and malleable. It’s the third most abundant metal on the earth’s crust, mainly obtained from bauxite. Aluminum is a silver-colored metal that is appreciated in aerospace, automotive, construction, and packaging industries among others. It has some properties like high corrosion resistance and good thermal and electrical conductivity that make it vital for many uses. Further, aluminum is 100% recyclable, therefore making it environmentally friendly to those manufacturers and consumers who prefer it.

The die casting moulds are one of the technology to manufacture aluminum alloys, such as ADC 12, A380, etc, of course there are other manufacturing technology that could make aluminum material, those include sand casting, extrusion molding, gravity casting, machining, etc.

Applications of Aluminum

  • Aerospace Industry: Aluminum has a large application in the aerospace industry in the form of fuselage frames, wings, and landing gears. Because of its lightweight and high strength, it can be used to improve the efficiency of burning fuel and the general performance of the aircraft.
  • Automotive Manufacturing: In the automotive industry, aluminum is applied to create engine blocks, bodies, wheels, and structures of vehicles. These properties make the car lighter hence giving better mileage and less pollution.
  • Construction and Architecture: Aluminum is widely used in the fabrication of windows, doors, roofs, and walls through the use of frames and sidings. Due to its durability, it does not corrode easily, and it is easy to maintain hence it is appropriate for use in homes and other buildings.
  • Packaging Solutions: Packing is another major application of aluminum, which is used in beer bottles, food tins, and aluminum foils. These properties make it an excellent material for the protection of the contents, it is light and can be recycled.
  • Electronics & Electrical applications: Aluminum is applied in heat sinks, housing, and connectors. Because of its good electrical conductivity, it is used in wiring and other electronic parts.
  • Consumer Goods: In consumer goods aluminum is widely used in kitchen utensils and furniture due to its modern look and strength. It is most commonly used in articles such as cookware, bicycles, and sports equipment.
  • Marine Applications: The corrosion resistance of aluminum makes it suitable for use in the manufacture of boat hulls, marine structures, and other parts that are likely to come into contact with seawater.
  • Industrial Equipment: In industrial applications, aluminum finds application in machinery parts, frames, and tooling since it is strong for its size and therefore reduces fatigue.
aluminum material

Machining Options for Aluminium

  • CNC Machining: CNC machining is a familiar technique used in the production of aluminum parts. It can be used to cut, drill, and mill shapes and sizes that are too intricate for other conventional methods.
  • Milling: Milling is a process, which uses rotating cutting tools to eliminate material from the workpiece. It is relatively easy to work with end mills and face mills hence suitable for carving designs.
  • Turning: In turning operations the aluminum workpieces are rotated and by using cutting tools material is removed to produce cylindrical forms. This method is particularly suitable for the manufacture of shafts, rods, and fittings.
  • Extrusion: Aluminum extrusion is a process of producing long lengths of profiles using aluminum through a die, including bars, tubes, and channels at high temperatures. It also enables a consistent cross-sectional shape of the structural members.
  • Die Casting: Die casting is a process of making complex aluminum parts through the forcing of molten metal into a mold. This technique is most applicable in high production volumes where the design is complicated.
  • Laser Cutting: Laser cutting gives clean and accurate cuts to aluminum sheets and parts. This technique is particularly suitable for intricate shapes and designs and, therefore, ideal for use in ornamental and practical design.
  • Waterjet Cutting: Waterjet cutting is the use of high-pressure water that is mixed with abrasives to cut aluminum. This method is well suited for thick materials and no heat-affected zones are created by this process.
  • Bending and Forming: Aluminum can be formed by using several techniques such as brake forming and roll forming because it is relatively easy to manipulate. These processes are applied in the production of structural parts and shells.

Introduction to Titanium

Titanium is a strong, yet light metal that is characterized by its high corrosion resistance and usually high durability. Titanium is the ninth most abundant component in the Earth’s crust and is obtained from ore like rutile or ilmenite. Being ~1.45 times lighter than steel and also being as strong as steel, titanium is suitable for all high-performance applications. Its ability to withstand corrosive conditions, that is, the ability to work effectively in marine, chemical, and high and low temperatures also makes it suitable for aerospace, medical, and marine applications. Moreover, titanium is biocompatible which makes it useful for use in medical implants and devices. The beneficial characteristics of Titanium are extensively important in the development of technology and innovations within several domains.

Applications of Titanium

  • Aerospace Industry: Titanium is widely applied in aerospace industries because of its high strength-to-weight ratio and high-temperature stability. This is used in parts that include frames, engines, and landing gear to enhance fuel efficiency and performance.
  • Medical Devices: Titanium is highly biocompatible and thus used in certain medical implants and medical-related products which include orthopedic implants, dental implants, fixtures, and cutting instruments among others. It is resistant to corrosion and can easily blend with bone hence making these products durable and efficient.
  • Marine Applications: In essence, titanium has excellent corrosion characteristics for seawater applications. The material is applied to such parts as hulls of ships, propellers, and other underwater parts where the presence of a highly resistant material is required.
  • Chemical Processing: In the chemical industry, the use of titanium is highly resistant to chemical and high-temperature uses. It is applied in heat exchangers, reactors, and pipes, which enables it to provide long-lasting services, especially in corrosive conditions.
  • Energy Sector: Some of the specific energy-related applications of titanium are offshore oil platforms and Gas and Oil power plants. High strength and excellent corrosion resistance make it suitable for use in parts that are exposed to hostile environments.
  • Automotive Industry: Titanium is used in high-performance vehicles for exhaust systems, and internal combustion engine parts, as well as lightweight structural members. Its strength is that it also lowers the weight of the vehicle while enhancing performance, which leads to fuel economy.
  • Sports Equipment: The major application of titanium is in sporting equipment like bike frames, golf clubs, and tennis rackets where lightness is important and strength is a must for long life.
  • Consumer Products: The use of titanium in consumer products is quite common since it provides strength, lightness, and a luxurious appearance to watches, jewelry, and tools.

Machining Options for Titanium

  • CNC Machining: CNC machining is a popular technique for fabricating complex and accurate titanium parts. This process enables fine-detail work and close-dimensional control and is used widely for fine-detailed work required in aerospace and medical applications.
  • Milling: It was found that milling of titanium can be done using appropriate tools and strategies. High-speed milling is used to reduce the material removal rate while preserving the integrity of the surface.
  • Turning: Turning operations are widely employed to manufacture cylindrical titanium parts. In this technique, the titanium workpiece is held stationary while the cutting tool is used to remove material to form shafts, tubes, and fittings while the workpiece is rotated.
  • Waterjet Cutting: A waterjet cutting method provides efficient cutting of titanium without heat which may alter the properties of the material. This technique is most applicable to complex shapes and thick materials.
  • EDM spark erosion machining: EDM stands for Electrical Discharge Machining which is used for completing shapes in titanium. It is a non-conventional machining process applicable to hard materials with a high level of accuracy in complex shapes.
  • Laser Cutting: Titanium can be laser cut for sheets and parts and the process yields exceptionally clean edges. This method is most suitable for fine work and work in thin materials.
  • Forming and Bending: Titanium can also be forged and bent by employing processes such as roll forming and press braking. These processes enable the generation of structural members and enclosures with the material’s properties retained.
  • 3D Printing (Additive Manufacturing): Titanium is more commonly used in additive manufacturing (3D printing) because of its benefits and the freedom of its designs. This technology can be used to create prototypes and build products that have a low density.
titanium vs aluminium

Titanium Vs. Aluminum: Benefits & Drawbacks

When selecting materials for engineering applications, it’s essential to weigh the advantages and disadvantages of titanium and aluminum alloy. Each metal has unique properties that make it suitable for different scenarios. The following table presents a logical breakdown of the key pros and cons of each material.

PropertyAluminumTitanium
WeightPros: Lightweight (density ~2.7 g/cm³), making it ideal for applications requiring weight reduction.Pros: Lighter than steel (density ~4.5 g/cm³), offering a good balance of strength and weight for demanding applications.
StrengthCons: Generally lower tensile strength (90-700 MPa) compared to titanium, which may limit its use in high-stress applications.Pros: High tensile strength (434-1,400 MPa), providing exceptional performance under load and in high-temperature environments.
Corrosion ResistanceCons: Moderate resistance; susceptible to pitting in harsh environments.Pros: Excellent resistance to corrosion, especially in marine and chemical environments, due to a protective oxide layer.
CostPros: Generally more economical; widely available and less expensive to produce.Cons: Higher cost due to complex extraction and processing methods, making it less accessible for some applications.
MachinabilityPros: Easy to machine with standard tools, making it suitable for high-volume production.Cons: More difficult to machine; requires specialized tools and techniques, which can increase manufacturing time and costs.
Thermal ConductivityPros: High thermal conductivity (205 W/mK), ideal for heat dissipation applications.Cons: Lower thermal conductivity (21.9 W/mK), limiting its effectiveness in applications requiring efficient heat transfer.
Electrical ConductivityPros: Excellent electrical conductor (3.5 x 10^7 S/m), suitable for electrical applications.Cons: Lower electrical conductivity (2.0 x 10^6 S/m), making it less suitable for electrical applications.
RecyclabilityPros: Highly recyclable, retaining its properties after recycling, contributing to sustainability.Pros: Also recyclable, though less commonly processed due to higher costs associated with titanium recycling.
ApplicationsPros: Versatile; used in automotive, aerospace, construction, and packaging due to favorable properties.Pros: Specialized applications; critical in aerospace, medical, and high-performance sectors where strength and durability are essential.
Heat ResistanceCons: Lower melting point (~660 °C); can deform at elevated temperatures, limiting high-heat applications.Pros: High melting point (~1,668 °C); performs exceptionally well in extreme thermal conditions.

How To Choose Between Titanium vs. Aluminum?

To assess the suitability of the two metals i.e. titanium or aluminum for an intended use then several technical factors as indicated below should be given due consideration. Titanium has a high strength-to-weight ratio, excellent corrosion resistance, especially in severe conditions, and is used in high-performance parts; however, it is relatively expensive with an average price between $10 and $30 per pound.

Aluminum, on the other hand, costs between $1.4 and $2 per pound, has good machinability and thermal conductivity and is ideal for production at large and in areas where weight is a major concern. One should also include costs of processing because titanium needs time and money to be machined while aluminum can be fabricated faster and cheaper. In the long run, it will be possible to make a proper assessment of these factors, especially the costs, as well as the requirements of the application, by which the proper choice of the material will be made.

Therer are lots of China die casting companies that make aluminum die casting parts and sell to the worldwide, so normally aluminum will be more popular in most of industries, of course some of industries must use titanium matreial.

Conclusion

In conclusion, the determination of which of the two metals to use when developing your civil engineering project depends on the specifications of your project. However, due to its higher costs as compared with other metals and difficult to machined properties titanium is finding its use in aviation and medical purposes because of its super strength, corrosion, and wear resistance. Whereas, aluminum is popular in its lightweight, easy-to-process, and relatively cheap material that can address almost any industry such as automotive and construction. Finally, the knowledge of the strengths and weaknesses, and the cost of each material type will enable the engineers and designers to come up with the best decision depending on the project objectives and operations.

Technical FAQs

Q1. What are the main disparities in strength between titanium and aluminum?

Titanium has a tensile strength between 434 to 1400 MPa while aluminum has a tensile strength of between 90 to 700 MPa therefore titanium is better for high stress.

Q2. Which material, titanium vs aluminum, has better corrosion resistance properties?

Titanium is more useful in corrosive conditions as it creates an oxide layer, and aluminum has only moderate corrosion and may pit under some circumstances.

Q3. How does weight play a role in the decision between aluminum and titanium alloy?

Aluminum is much lighter (density ~2.7 g/cm³), which makes it preferable to use in weight-sensitive applications, whereas the density of titanium is ~4.5 g/cm³ gives it higher strength, and thus its weight can be explained by high-performance certain applications.

Q4. How do machining costs Influence titanium aluminum alloy?

Aluminum is easier to machine and cheaper than titanium, which needs specific instruments and processes, thus, the high cost of labor and processing.

Q5. What industry is each metal mainly utilized in? Titanium is widely used in aerospace, medical sectors, automobiles, etc., and Aluminum is used in automobile industries, construction, packaging, and other industrial sectors due to its cheap rate and uses.

Die-casting mold

We often need metal parts in various shapes. We use them in our cars, houses, machines, and other infrastructures. Have you wondered how it is possible to make such a detailed shape? Die Casting mold tech has revolutionized our lives. With this method, you can create complex shapes and patterns. Die-casting mold parts are widely prevalent in a wide range of applications.

In this article, we will learn some fundamentals about die-casting mold. In addition, it’s gonna be an excellent guide for those looking for the best die-casting services. You will learn how foundries make die-casting molds. So, sit tight and read this article thoroughly.

die casting mold

Overview of Die Casting

Die Casting is a famous type of metal casting process. As the name implies, this method typically uses specific dies for the job. The shape of the final metal part depends on the shape of the dies. Although there are different types of die casting, the base technology is the same for all. The material used for making these molds is hardened tool steel.

Die casting has a long history. People invented this tech in 1838. In the early times, this application was only for printing purposes. Later, as technology developed, people usually learned how to use this method to create various complex metal parts. Die casting offers several benefits.

  • Die-casting mold typically offers high production efficiency. This part is comparatively faster than other permanent mold casting processes. As a result, you can create hundreds of metal parts in less time.
  • Die-casting mold parts usually come with a smooth surface finish. For HPDC metal parts, this is more obvious. As a result, you might not need additional machining services.
  • The die-casting method is versatile. It generally works with many metals, including aluminum, zinc, and magnesium.
  • Since this method is fast, it generally reduces production costs. Although creating the dies may be expensive, this method is cheaper in the long run.
  • Die-casting mold parts are widely prevalent in many industries. This method makes your car’s engine, gearbox, and structural parts. You may also find similar applications in other sectors as well.

Different Types of Die Casting

Die casting typically has six major types, each with its own perks. Each type is suitably suited to specific applications. Let’s look at their particular technology and product use.

Type #1 HPDC (High Pressure Die Casting)

As the name suggests, this die-casting method requires high pressure for the job. This high pressure die casting technically pushes the molten metal to every mold corner. As a result, you can get very precise metal parts.

In the car industry, engine blocks and gearbox castings are made of high-quality HPDC aluminum parts. Various equipment and infusion pumps are noteworthy in the medical industry. Besides, many aircraft components also need HPDC casting metal parts.

Type #2 LPDC (Low-Pressure Die Casting)

This die-casting method is just the opposite of HPDC. It involves low pressure, typically ranging from 2 to 15 psi. The process is almost similar, but it is generally slower than HPDC. Since it is slow, you can easily control the movement of the molten metal.

LPDC metal parts are widely prevalent for car wheels, cylinder heads, and suspension systems.

Type #3 Gravity Die Casting

This die-casting method uses gravitational force to fill the mold with molten metal. The process typically pours the molten metal into the mold from above, and the liquid flows downwards. It is simple and cheap because it doesn’t need additional forces.

The gravity die-casting method is prevalent in making pipe fittings and various cookware.

Type #4 Vacuum Die Casting

As the name suggests, this casting method involves creating a vacuum environment. It does this before inserting the molten metal. As a result, you don’t get any casting defects caused by trapped gas inside.

Vacuum die casting is suitable for making delicate components. Electronic castings, aircraft parts, and some automotive parts are noteworthy examples.

Type #5 Squeeze Die Casting

Squeeze die casting combines casting and forging. After injecting the molten metal inside the mold, the process applies high pressure during solidifying. Squeeze pressure mainly reduces the porosity defects.

Squeeze die casting is widely popular because of the high strength and density of the metal parts. Some common examples are suspension parts, brackets, and some building components.

Type #6 Semi Solid Die Casting

This process also combines casting and forging. The only difference is that this process uses semi-solid metals. It looks like a slurry consistency. SMDC is highly popular for making many car parts, electronic housing, and medical devices. go to simi solid aluminum die casting page to know more.

What is Die Casting Mold?

The tool used in the die-casting method is generally called a die-casting mold. People also call it a die-casting tool. The process of making this tool is known as die-casting tooling.

The definition says that a die-casting mold is a unique tool used in the die-casting process. Its primary purpose is to shape molten metal into desired forms. In most cases, they generally come with two halves: the fixed and moving die half.

When both halves are closed, they form a cavity inside that mimics the desired part’s shape. A high-quality die-cast mould is essential to ensure the highest accuracy of your finished metal parts. However, there are several components:

Mold Cavity

The hollow space inside a Mold is generally the mold cavity. It actually gives the shape and size of the final metal part. The molten metal is injected into this cavity and solidifies to get the desired form. Note that you must ensure high precision when making this cavity.

Core Pin Die Casting Mold

The core is another vital component of a die-casting mold. It creates features in casting, such as holes or recesses. It mainly creates complex geometries within the metal part. However, depending on the requirements, you can make it using sand or metal. Note that this core must withstand high pressure and temperature during operation.

Ejector Pins

As the name implies, these pins basically eject the movable die-cast mold half from the fixed one. During the design process, engineers carefully place them where they can apply even pressure. The correct design always ensures that the part is not damaged.

Runner System

The runner generally channels the molten metal into the mold cavity. It consists of several tracks that go to different parts of the mold. Proper runner system design is crucial for even distributing molten metal. Overall, an adequate runner system significantly reduces defects.

Overflow System

The overflow system collects excess molten metal during the injection process. As a result, the system can prevent defects caused by trapped air. Note that this system may not be present for some die-casting molds.

Others

Elements like bolts and pins hold the die-cast mold system together. These parts need to be strong and carefully machined. The die-casting method requires high pressure, gas pressure, and heat. Choosing the right materials is crucial to keeping these parts in good shape.

Die Casting Mold Material: Hardened Tool Steel

Hardened tool steel is a general type of steel. It has various grades suitable for specific use. You can achieve steel’s high hardness and strength by the heat-treatment method. However, why are these tool steels so popular?

First, they offer high wear resistance. Second, their toughness usually makes them ideal for many machining jobs. Third, they also give stable dimensions. Finally, and most importantly, they can withstand extreme heat. As you know, this property is crucial for die-casting jobs.

Hardened tool steel has five different groups. Each group is ideal for unique applications.

Cold-working Die Casting Mold Material

The following four grades are widely prevalent in die-casting mold manufacturing.

Grade Carbon Manganese Silicon Chromium Nickel Molybdenum Vanadium
O6 1.45% 1.00% 1.00% 0.8-1.4%
A3 1.25% 0.50% 5.00% 0.30% 0.9-1.4% 0.8-1.4%
A6 0.70% 1.8-2.5% 0.9-1.2% 0.30% 0.9-1.4%
D2 1.50% 0.45% 0.30% 11.0-13.0% 0.90% 1.00%

die casting mold equipment

Hot-Working Die Casting Mold Materials

As the name suggests, these materials are subjected to high temperatures during casting. They are ideal for HPDC die-casting molds. There are various grades: Grades H1 to H13 are usually chromium-based alloys. On the other hand, tungsten alloys are from H20 to H39, and molybdenum-based alloys are from H40 to H59.

Other types

There are other types of die-casting mold steels as well. SKD61, 8407, DIN 1.2343, 2083, and 8418 are noteworthy. These steels offer specific properties. As you know, die-casting methods have different types. Therefore, materials also vary based on these types.

Three Common Types of Die Casting Mold

We can generally divide molds into three types based on the number of cavities. This diversity mainly arises due to specific needs. Different cavity designs allow die-cast mold makers to produce parts rapidly.

Type #1 Single-cavity Dies

As the name suggests, these die-cast molds have a single cavity. Using these dies, you can produce one metal part per cycle. People widely use these molds for simple and low-volume orders.

Using these dies makes design easier, which is their main advantage. However, the speed of output is slower than with multi-cavity dies.

Type #2 Multi-cavity Dies

Multi-cavity dies have more cavities. Using these dies, you can produce multiple metal parts per cycle. This means you can produce more products than single-cavity dies. Therefore, multi-cavity dies are ideal for high-volume orders.

The best thing about these dies is that they offer cheaper production costs. However, they usually have complex designs.

Type #3 Family Molds

In multi-cavity dies you will find the same cavity design but multiple times. You can generally create multiple metal parts per cycle. However, in family molds, these designs are different. So, in one sense, all family molds are multi-cavity molds, but all multi-cavity molds are not family molds.

Aluminum Die Cast Mold: Market Trends

The aluminum die-cast mold market will grow significantly in 2024. According to Persistence Market Research, this market was valued at $301.3 million in 2023. In the future, this sector is expected to grow steadily at 4.8% every year. Experts expect this market will reach up to $481.6 million in 2033.

How are Die Casting Molds Made?

In the preceding section, we have briefly discussed various die-casting methods and molds or tooling types. In this section, we will generally focus on how they are made. You will be familiar with the step-by-step process in every die-casting factory. So, you will know every step of making the molds whenever you plan to make unique metal parts. This is actually important for custom metal parts manufacturing.

Step #1 Designing the Mold

This step is perhaps one of the most important aspects of the process. Here, you will decide how you wish your metal part to appear and what steps will be involved in manufacturing it. Depending on the part’s design, the type of die-casting method must also be properly selected.

Two parameters are essential in this case: a dimensional analysis and a geometric perspective. The dimensional view informs you of how many cavities your metal part has. Which of the single-cavity or multi-cavity or family mold types is required? This design also makes it easy for you to determine the pressure and volume of the casting.

A geometric view that informs you of the level of complication of the metal part and your plan on how to open and eject it. However, it is very important to note the kind of parting line that is used here. You must ensure that this parting line will coincide with the mold opening direction.

Similarly, a die-casting company also considers other important aspects during this step. We will briefly discuss those in the next section.

Step #2 Choosing the Material

The die-casting method usually involves varying pressure and temperature. Therefore, you must select material that is highly compatible with these situations. In general, engineers use various types of tool steels here. In the previous section, we have discussed these tools steel in detail.

Step #3 Machining the Mold

Once your design and materials are ready, you must plan how to shape the die-cast mold. In this case, various machining methods play a crucial role. Engineers prefer CNC machines for making die-casting molds.

As you know, CNC machining offers exceptional precision. You can technically achieve tolerance up to 0.01mm. You have options like CNC milling, drilling, turning, boring, and more.

Step #4 Heat Treatment

Various heat treatments are very important in die-casting mold making. This step significantly improves the machined parts’ strength and durability. Besides, the process makes the mold more resistant to wear and tear.

Common heat treatment methods are quenching, tempering, annealing, and stress relieving. These methods typically ensure the die-cast mold performs well during die-casting.

Step #5 Finishing

After heat treatment, the new die-cast mold needs some finishing touches. These steps are crucial to ensure smooth surfaces and precise dimensions.

Finishing techniques may include polishing, grinding, and sandblasting. The main purpose of all these techniques is to give the die-casting mold parts smoother and better textures. As a result, they can achieve high tolerances.

Step #6 Assembly if necessary

There are times when you may need to make die-cast mold parts separately. When there are many parts, assembly must always be done carefully. The die-casting mold factory always checks to ensure the assembly is lined up correctly.

Step #7 Testing

Once all the steps above are done, die-cast mold manufacturers test these molds in the lab. They run tests to ensure the mold is in good shape and works correctly. These tests tell you that the molds are high-quality.

die casting mold

Key Steps in Die Casting Mold Design

As mentioned in the last part, several key factors are considered when designing a die-casting mold. This section will mainly discuss those and discover why they are crucial in die-cast mold manufacturing.

Actual Part Design

Before making the die-casting mold, engineers create the part itself. For this job, they use various 2D and 3D drawing programs. In most die-cast mold factories, graphic designers typically use SolidWorks or AutoCAD.

During visual testing, you need 2D models. Engineers use this drawing to check the sizes after each stage of production. A well-designed part gives high-quality results. So, whenever you work with a manufacturer, make sure they have these plans before they start making the product.

Die Casting Injection Molding Type

This is a very important factor when making a die-casting mold. Usually, it changes the quality, strength, and finish of the finished part.

Based on this injection, there are six different types: HPDC, LPDC, Vacuum, and more.

When designing the injection type, several factors need to be considered. First, what type of metal are you working with? Second, did you consider parting lines, geometric views, and design details? Third, what is your expected production speed?

When you use the right injection type, the mold will always fill properly, and casting flaws will be less common. Also, the right pick cuts cycle time by a large amount. In general, you can get very good output.

Gate And Runner Design

The gate and runner channel molten metal into the die-casting mold and usually control the flow of the liquid. Proper design ensures smooth and efficient filling and reduces various types of casting defects.

Consider size, location, and shape when designing a gate and runner. The gate must be placed in the right place to minimize turbulence.

Die Casting Mold Base Design

The mold base typically supports and aligns all mold parts. When designing, ensure you have created a robust design. It provides the system’s overall stability.

You should consider the material and temperature here. The mold base must withstand high pressure and temperature. You should also check for proper alignment and fit.

Cooling System

The cooling system helps the mold solidify the molten metal. A proper cooling system typically improves production speed and part quality. However, inappropriate cooling can cause various casting defects. Therefore, ensure an appropriate cooling system when designing a mold.

There are different kinds of cooling systems. People often use water lines and cooling inserts. Cooling plugs are great for places that need to cool down quickly. When you design a mold cooling system, try to balance the heat across the mold.

Venting and Ejection System

The ventilation and ejection system mainly removes trapped air from the mold. The trapped air could either be created by mold or be there before the injection.

When designing a mold, place the vents at high points. In this case, you can use thin vents to avoid flash. Also, put the ejector pins in the right place to prevent damage.

Note that effective venting and ejection systems usually improve part quality. Overall, it reduces cycle times and production efficiency.

Simulation

Once you have considered all the factors above, the simulation shows you precisely what you have designed. Simulations can help you find flaws and issues with the flow of metal. Die-cast Mold Makers typically use software like MAGMASOFT, ProCAST, and Flow-3D.

Frequently Asked Questions

What metals are used in die casting?

In die casting, the common metals are aluminum, zinc, magnesium, lead, pewter, and copper. These metals are popular due to their low melting point. Besides, they also offer excellent casting properties, strength, and durability. Among all these metals, aluminum is the most popular. It is lightweight and has an excellent strength-to-weight ratio.

Is 4140 a tool steel?

Yes, LSS 4140 steel is a type of tool steel. This alloy offers excellent hardness, strength, and wear resistance. It is an excellent tool steel for most machining jobs. More specifically, you can find its use in various rotating components. For example, axles, drive shafts, gears, and spindles are noteworthy.

What kind of steel is used for die casting?

The kind of steel mainly varies based on the type of die-casting method. For HPDC die-casting molds, H series tool steels are widely prevalent. On the other hand, for LPDC or cold-working jobs, the O, A, and D series of steel tools are famous. Some special grades are also there, like SKD61, 8407, and 8418.

Summary

Die casting is crucial for making many complex metal parts. You can create die-casting parts through various methods. HPDC and LPDC are the two most common methods you will use in a die-casting mold company.

Die-casting mold has three types:  single-cavity, multi-cavity, and family molds. Each type is suitable for specific production requirements.

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