Aluminum Die Casting -Precision Parts from KastMfg

Aluminum die casting is KastMfg's core capability and the foundation of our manufacturing business. We have been producing aluminum die castings for over 20 years, operating a dedicated aluminum HPDC facility with 16 cold-chamber machines from 160T to 1,600T. Our production capacity exceeds 10,000 tonnes of aluminum castings per year, serving customers in automotive, industrial machinery, electronics, LED lighting, and telecommunications.

Aluminum is the world's most widely used die casting metal. Its combination of low density (2.74 g/cm³), high strength, excellent thermal conductivity (96 W/m·K), and natural corrosion resistance makes it the preferred choice for automotive lightweighting, thermal management, structural enclosures, and precision industrial components.

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Aluminum Alloys We Cast

Alloy	Standard	Composition	Tensile (MPa)	Yield (MPa)	Key Properties	Best Applications
A380	ASTM B85	Al-8.5Si-3.5Cu	317	159	Best overall: fluidity, machinability, strength	General engineering, motor housings, gearbox covers
ADC12	JIS H5302	Al-11Si-2Cu	310	160	Excellent machinability, tight tolerances	Automotive engine/transmission, Japanese OEM supply
A360	ASTM B85	Al-9.5Si-0.5Mg	317	172	Superior corrosion resistance, good ductility	Marine, outdoor, coastal environments
A413	ASTM B85	Al-12Si	290	145	Best pressure tightness, near-eutectic	Hydraulic manifolds, valve bodies, pressure-tight castings
A390	ASTM B85	Al-17Si-4.5Cu	280	240	High hardness, wear resistance	Cylinder liners, pistons, wear surfaces

A380 -The Workhorse Alloy

A380 accounts for the majority of aluminum die casting production globally, and for good reason. Its silicon content (8.5%) provides the fluidity necessary to fill complex cavities and thin walls reliably. Its copper content (3.5%) contributes strength and machinability. A380 is not the best alloy in any single property category, but its combination of properties is unmatched for general-purpose engineering castings.

ADC12 -The Japanese Standard

ADC12 is the Japanese Industry Standard (JIS) equivalent of A380, with slightly higher silicon (11%) and lower copper. It is specified by Japanese OEM automotive and electronics customers and produces excellent dimensional accuracy and machinability. KastMfg regularly supplies ADC12 castings to Japanese Tier 1 automotive suppliers and their global plants.

A413 -When Pressure Tightness is Required

A413's near-eutectic composition (12% silicon) produces the finest solidification microstructure of the aluminum die casting alloys, with the lowest shrinkage and best resistance to gas porosity. For hydraulic manifolds, pneumatic valve bodies, and pressure-tight enclosures, A413 with vacuum-assisted casting eliminates the need for post-cast impregnation in most applications.

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Technical Capabilities

Parameter	KastMfg Specification
Experience	20+ years aluminum die casting
Machine tonnage	160T -1,600T (16 cold-chamber machines)
Alloys	A380, ADC12, A360, A413, A390
Dimensional tolerance	CT4-CT6 per ISO 8062
Min wall thickness	1.2 mm standard; 0.8 mm achievable
Max projected area	Up to 2,000 cm² (1,600T machine)
Surface finish (as-cast)	Ra 1.6-2.2 μm
Weight range	0.05 kg -25 kg
Annual capacity (aluminum)	10,000+ tonnes
Shot monitoring	Velocity, pressure, temperature -logged every shot

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Secondary Operations for Aluminum Die Castings

KastMfg delivers fully processed, ready-to-assemble aluminum components. Secondary operations available in-house:

CNC Machining

• 3-axis, 4-axis, and full 5-axis simultaneous machining
• Precision boring to H6/H7 (bearing seats, shaft bores)
• Face milling of sealing surfaces to 0.01 mm flatness
• Thread milling, drilling, tapping to M30
• 18 machining centers; two shifts

Heat Treatment

• T5 (artificial aging) -improves hardness and yield strength by 20-30%
• T6 (solution + artificial aging) -available on vacuum-assisted die cast parts with adequate low porosity
• Third-party T6 treatment coordinated for standard HPDC parts requiring impregnation

Surface Finishing

• Shot blasting (standard preparation)
• Powder coating (full RAL/Pantone color range)
• Type II anodizing (5-15 μm, clear or dyed)
• Type III hard anodizing (25-100 μm, 60+ HRC)
• Chromate conversion coating (Alodine) -conductive, pre-paint treatment
• E-coating -internal surface coverage

Assembly

• Threaded inserts (helicoil, keensert, press-fit)
• Bearing press-fitting
• Sub-assembly with mating components

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Quality Control for Aluminum Castings

Incoming alloy verification: Every melt batch verified by OES spectrometer for chemistry conformance to A380, ADC12, A360, or A413 specification.

Process monitoring: Injection velocity, peak pressure, intensification pressure, and die temperature logged every shot. SPC charts maintained for critical process parameters.

Dimensional inspection: CMM first article inspection (100-piece dimensional study on all features). Production SPC on critical dimensions.

Internal soundness: X-ray inspection available for pressure-critical applications. Vacuum-assisted casting with VADC for near-zero porosity requirements.

Mechanical properties: Tensile testing available on witness specimens cast with production batches for programs requiring mechanical property certification.

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Industry Applications

Automotive and EV

KastMfg supplies aluminum die castings to automotive Tier 1 customers worldwide. Common parts:

• Gearbox and transmission housings (A380, ADC12)
• EV motor housings and inverter enclosures (A380, vacuum HPDC)
• Battery tray structural members (A380, 1,000T-,600T machines)
• Brake caliper bodies and booster brackets

Industrial Machinery

• Hydraulic manifold blocks (A413 -pressure tightness)
• Motor end shields and fan covers (A360 -corrosion resistance)
• Gearbox and reducer housings (A380)
• Compressor crankcases

Electronics and Telecommunications

• Heat sinks and thermal management housings (A360 -thermal conductivity)
• 5G base station enclosures and antenna housings
• Server chassis components
• RF shielding enclosures

LED Lighting

• Streetlight and high-bay fixture housings
• LED heat sink bodies
• Floodlight and architectural lighting enclosures

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Frequently Asked Questions

What is the minimum order quantity for aluminum die casting?

No formal MOQ. Prototype programs from 50-100 pieces using P20 prototype tooling. Production minimum typically 500-1,000 pieces per run. Annual programs of 10,000-1,000,000+ pieces are routine.

How long does aluminum die casting tooling take?

Prototype (P20 steel, single-cavity): 3- weeks from drawing approval. Production (H13 steel, single-cavity): 5- weeks. Multi-cavity or complex slide tools: 7-10 weeks.

What tolerances can you hold on aluminum die castings?

Standard: CT5 per ISO 8062 (±0.1-0.3 mm on most linear dimensions). With CNC post-machining: ±0.02-0.05 mm on critical features. Provide your drawing and we will confirm tolerance feasibility during the DFM review.

Can aluminum die castings be T6 heat treated?

Standard HPDC aluminum contains gas porosity that causes surface blistering during T6 solution treatment. T6 is possible on vacuum-assisted HPDC (VADC) parts with low porosity, or on gravity die cast / LPDC parts. KastMfg offers VADC for programs requiring T6.

Do you offer DFM review before tooling commitment?

Yes. Every KastMfg inquiry begins with a complimentary DFM review. We examine draft angles, wall thickness, undercuts, tolerance feasibility, and gating options, and return a written DFM report within 48 hours.

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Request an aluminum die casting quote: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China