ALUYONIX Precision Die Casting
CASTING PROCESS METHODOLOGY

Low Pressure Die Casting (LPDC)

Bottom-up controlled filling producing dense, defect-free structural castings.

Process Metallurgy & Overview

In Low Pressure Die Casting, molten metal is housed in an airtight furnace beneath the die. Dry air or inert gas at 0.2 to 1.5 bar smoothly pushes the melt up a ceramic riser tube into the cavity from the bottom, completely eliminating turbulent oxidation and gas entrapment.

Working Principle & Operational Steps

1Sealed holding furnace pressurized with dry nitrogen or compressed air.
2Laminar molten stream rises calmly through the refractory stalk tube into the preheated steel mold.
3Directional solidification proceeds from top to bottom while pressure is maintained, feeding thermal shrinkage.
4Pressure drops, unsolidified metal drains back into the crucible, and the casting is demolded.

Technical Parameter Specifications

Clamping Force
Automated 4-column hydraulic rigs
Wall Thickness
3.0 mm – 30.0 mm
As-Cast Tolerance
±0.10 mm to ±0.30 mm
Cycle Rate
8 – 18 shots/hr
Surface Finish
Ra 3.2 – 6.3 µm
Primary Alloys
Aluminium A356, A357

Ideal Applications

  • Automotive and EV alloy road wheels (passenger and commercial vehicles)
  • Structural suspension knuckles, subframes, and steering crossmembers
  • Marine propulsion impellers and cylinder heads
  • High-pressure gas meter and regulator manifolds

Key Advantages

  • Laminar filling eliminates oxide inclusion and air pocket entrapment
  • Outstanding metallurgical density and ductility with full T6 heat-treatability
  • High material yield (often 85–90%) due to absence of extensive runner systems
  • Superior fatigue strength comparable to forged aluminium

Engineering Trade-offs

  • Slower cycle times (3 to 8 minutes per cycle) compared to HPDC
  • Minimum wall thickness typically restricted to ≥ 3.0 mm
  • Requires precise die temperature control with oil/water thermal circuits

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