Aluminium High Pressure Die Casting

Updated on: 17 Feb 2025

Die casting is a popular method of shaping aluminium through pre designed die made from hardened tool steel.

In order to understand what is aluminium high pressure die casting we need to understand that there are 2 methods through with die casting can be done for aluminium. One is traditional, low pressure die casting and the other is modern high pressure die casting

Methods of Aluminium Die Casting:

High Pressure Die Casting

Molten liquid metal is pourted into pre designed and manufactured hardened tool steel molds. They are perfect to withstand high pressure and high temperature of die casting molten metal. During this process liquid aluminium can be between 650°C to 750°C (1202°F to 1382°F). A hydraulic piston or plunger is used to rapidly inject the molten metal into the die cavity. The die is tightly clamped shut to withstand the high pressure during the injection process.

Low Pressure Die Casting

Same as high pressure die casting - molten liquid metal is pourted into pre designed and manufactured hardened tool steel molds. In this method gravity comes into action while pouring liquid metal into molds. Temperature of liquid metal is again between 650°C to 750°C (1202°F to 1382°F) but pressure is not as high as high pressure die casting.

However natural setteling of liquid metal results into higher strength. The surface will not be as smooth as high pressure and the resultant die casted metal will require machining.

Pros of Aluminium High Pressure Die Casting

1. Casted metal surface is smoother
2. Casted metal can be casted into casts that have wall thicknes of less than 3mm
3. Faster and can be used to manufacturing in bulk, due to automation and no human intervention

Pros of Aluminium Low Pressure Die Casting

1. Casted metal surface is not as smooth but is stronger than high pressure casts
2. Casted metal requires a minimum wall thicknes of 3mm
3. Slower and human intervention is needed in the process
4. Casted metal requires machining to smooth out the surface and remove unwanted metal shavings