ALUYONIX Precision Die Casting
CASTING PROCESS METHODOLOGY

High Pressure Die Casting (HPDC)

High-speed automated injection for complex, thin-walled precision components.

Process Metallurgy & Overview

High Pressure Die Casting forces molten aluminium or zinc under immense pressure (300 to 1,200 bar) into reusable hardened tool steel dies at speeds up to 60 m/s. It delivers near-net-shape geometry, exceptionally smooth surface finishes, and rapid cycle times.

Working Principle & Operational Steps

1Molten alloy is dosed into the cold chamber shot sleeve via automated robotic ladle.
2A multi-stage hydraulic plunger accelerates the metal at micro-second velocity curves into the evacuated die cavity.
3Sustained intensification pressure packs the liquid metal, compensating for volumetric solidification shrinkage.
4The multi-part die opens, automated hydraulic ejector pins push the part out, and an extraction robot retrieves it for quench and trim.

Technical Parameter Specifications

Clamping Force
120T – 2,500 Tonnes
Wall Thickness
1.2 mm – 8.0 mm
As-Cast Tolerance
±0.03 mm to ±0.15 mm (as-cast)
Cycle Rate
25 – 80 shots/hr
Surface Finish
Ra 1.6 – 3.2 µm
Primary Alloys
Aluminium A380, ADC12

Ideal Applications

  • Automotive EV motor housings and inverter enclosures
  • Engine oil pans, transmission covers, and bracket systems
  • Telecommunications 5G heatsinks with dense thin fins
  • Pneumatic and hydraulic valve manifolds

Key Advantages

  • Rapid cycle times (20 to 90 seconds) ideal for high-volume automotive production
  • Ultra-thin wall capability down to 1.2 mm without cold shuts
  • Superb dimensional repeatability (ISO 8062 Grade DCTG 4 to 6)
  • Exceptional surface finish (Ra 1.6 – 3.2 µm) ready for powder coating or e-coating

Engineering Trade-offs

  • High initial tooling investment (economical primarily at > 5,000 pcs/year)
  • Trapped air risk requiring vacuum assist if heat treatment (T6) is necessary
  • Tool geometry limited to parting line pull without complex collapsible cores

Evaluate Feasibility for Your Part in HPDC

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