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Enhanced Reflectivity Aluminum Die Casting LED Housing with Mirror Polished Finish
Introduction to Aluminum Die Casting Process:
The Aluminum Die Casting process is a highly efficient manufacturing method used to produce lightweight, durable, and complex metal parts with excellent dimensional accuracy. This process involves injecting molten aluminum alloy into a steel mold (or die) under high pressure, allowing for the mass production of components with intricate designs and fine details.
Key Steps in the Aluminum Die Casting Process:
1. Mold Preparation: A steel mold is designed and fabricated to match the desired part geometry.
2. Melting: Aluminum alloy is melted in a furnace at temperatures typically ranging from 660°C to 760°C (1220°F to 1400°F).
3. Injection: The molten aluminum is injected into the mold cavity at high pressure, ensuring it fills every detail of the mold.
4. Cooling: The molten aluminum solidifies quickly inside the mold, taking the shape of the cavity.
5. Ejection: The solidified part is ejected from the mold, and any excess material (such as flash) is trimmed.
6. inishing: Additional surface treatments, such as machining, polishing, or coating, may be applied to meet specific requirements.
Key Parameters for Aluminum Die Casting:
| Parameter | Details |
| Material | Aluminum Alloys (e.g., A380, A383, ADC12, 6061) |
| Melting Temperature | 660°C - 760°C (1220°F - 1400°F) |
| Injection Pressure | 10,000 - 30,000 psi |
| Mold Material | Tool Steel (e.g., H13, P20) |
| Tolerance | ±0.1 mm (±0.004 in) for small parts |
| Wall Thickness | 0.5 mm - 5 mm (0.02 in - 0.2 in) |
| Surface Roughness | 1.6 - 3.2 µm (63 - 125 µin) |
| Cycle Time | 10 - 60 seconds (depending on part size and complexity) |
| Part Weight Range | 0.1 kg - 10 kg (0.22 lbs - 22 lbs) |
| Common Surface Finishes | Anodizing, Powder Coating, Polishing, Sandblasting, Electroplating |
| Applications | Automotive, Aerospace, Electronics, Consumer Goods, Industrial Equipment |
Advantages of Aluminum Die Casting:
1. Lightweight: Aluminum is inherently lightweight, making it ideal for applications where weight reduction is critical.
2. High Strength-to-Weight Ratio: Aluminum die-cast parts offer excellent strength while remaining lightweight.
3. Complex Geometries: The process allows for the production of intricate shapes and thin-walled components.
4. Excellent Surface Finish: Parts produced have smooth surfaces, often requiring minimal post-processing.
5. Corrosion Resistance: Aluminum naturally resists corrosion, and additional surface treatments can enhance this property.
Common Surface Treatments for Aluminum Die Casting:
1. Anodizing: Enhances corrosion resistance and provides a decorative finish.
2. Powder Coating: Adds a durable, wear-resistant layer in various colors.
3. Polishing: Creates a smooth, reflective surface for aesthetic or functional purposes.
4. Sandblasting: Provides a uniform matte finish and improves surface texture.
5. Electroplating: Adds a protective layer (e.g., zinc or nickel) for enhanced durability
