Key design factors for aluminium die casting. Here are some additional points that can improve their effectiveness:

1.Material selection:

Selection of the right aluminium alloy is critical to achieving the required mechanical properties, surface finish and overall performance of the final part. Factors such as strength, corrosion resistance and thermal conductivity should be considered when selecting materials.

2.Rounded corner design:

Incorporating rounded corners at the joints of different parts helps to reduce stress concentrations, thereby increasing the durability and life of the part. Proper fillet design also aids in the flow of molten metal during the casting process.

3.Surface finish requirements:

Determine surface finish requirements early in the design phase to ensure that the die casting process will achieve the desired smoothness or texture. Consider post-die casting operations such as machining, polishing or coating to meet aesthetic and functional specifications.

4.Thermal management:

Efficient cooling channels within the mould help control the solidification process and minimise the formation of internal defects such as shrinkage porosity. Proper thermal management improves the dimensional accuracy and mechanical properties of castings.

5.Design for Manufacturability (DFM):

Implementing design for manufacturability (DFM) principles ensures that the design is optimised for the die casting process, thereby reducing production costs.

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