{"id":1966,"date":"2025-02-25T16:06:21","date_gmt":"2025-02-25T08:06:21","guid":{"rendered":"https:\/\/www.hexinmusu.com\/?p=1966"},"modified":"2025-02-27T11:13:27","modified_gmt":"2025-02-27T03:13:27","slug":"about-detail-43","status":"publish","type":"post","link":"https:\/\/www.hexinmusu.com\/en\/about-detail-43.html","title":{"rendered":"What is the difference between aluminum extrusion and aluminum die casting?"},"content":{"rendered":"

As an engineer deeply involved in aluminum alloy forming for more than 20 years, I am often asked about the core differences between aluminum extrusion and aluminum die casting. In this article, I will combine the high-pressure\/low-pressure\/gravity casting practical experience to make a systematic comparison from material science, process principle to business decision.<\/p>\n\n\n\n

What is aluminum extrusion?<\/h2>\n\n\n\n
\"aluminum<\/figure>\n\n\n\n

Aluminum extrusion is a solid-state process of extruding through a die and is part of theSolid State Plastic Molding<\/strong>, commonly used in the production of assembly line aluminum profiles, heat dissipation aluminum parts, and so on. At its core, aluminum rods heated to a plastic state (400-500\u00b0C) are fed into an extruder and forced through a die with a specific cross-sectional shape to form a continuous profile, which can be used to manufacture long-sized products such as door and window frames, guide rails and other products (longitudinal lengths of up to 10 meters or more).<\/p>\n\n\n\n

Advantages of aluminum extrusion<\/strong>\u200b
Aluminum extrusion products have lightweight, corrosion-resistant characteristics, low tooling investment costs (about 30,000-200,000 yuan), the surface of the anodic oxidation treatment of the oxide film thickness of up to 0.012mm, presenting a bright texture, and no need for plating to meet the basic corrosion requirements. Can produce ultra-long one-piece molding structure, such as photovoltaic bracket rail (length of 12 meters, wind pressure > 3.5kPa).<\/p>\n\n\n\n

Disadvantages of aluminum extrusion<\/strong>\u200b
The process is prone to warping and deformation, black lines, bumps and other surface defects, unoxidized aluminum still exists in the risk of rust, longitudinal strength is only 60%-70% of iron products. anodic oxidation layer of abrasion resistance is weaker than the electroplating process, and the overall cost of iron products than the high 3-4 times, for example, the building curtain wall profiles processing fee of about 25 yuan \/ kg, while the galvanized steel is only 8 yuan \/ kg.<\/p>\n\n\n\n

What is aluminum die casting?<\/h2>\n\n\n\n
\"Aluminum<\/figure>\n\n\n\n

Aluminum die casting belongs toLiquid High Pressure Casting<\/strong>The 680-720\u00b0C molten ADC12 alloy will be used to50-120MPa<\/strong>Pressure injection into the steel mold, in 20-60 seconds to complete the full process of filling - solidification - demolding. Its essence is the non-equilibrium solidification process of metal under super-rapid cooling (>100\u2103\/s). It is suitable for the production of complex thin-walled parts such as automobile parts and 3C housings, and the cycle time of a single piece can be shortened to less than 30 seconds.<\/p>\n\n\n\n

Advantages of Aluminum Die Casting<\/strong>\u200b
The high hardness of the die casting (A380 alloy has a tensile strength of 320MPa) allows for one-piece molding of complex features such as threaded holes and reinforcement bars, eliminating the need for subsequent cutting processes. Zinc-aluminum alloy hybrid die casting can also enhance wear resistance, such as automotive transmission housing can be reduced by 60% assembly parts through this process.<\/p>\n\n\n\n

Disadvantages of Aluminum Die Casting<\/strong>\u200b
Mold development costs are high (about 200,000-2 million yuan), and the difficulty of modifying the design errors, you need to rely on 10,000-piece orders to share the cost. For example, a new energy vehicle door lock shell die-casting mold offer of 850,000 yuan, while the injection mold only needs 150,000 yuan.<\/p>\n\n\n\n

Core Differences Comparison Table<\/strong>\u200b<\/h2>\n\n\n\n
\u200bcomparison dimension<\/strong>\u200b<\/th>aluminum extrusion<\/th>aluminum die casting<\/th><\/tr><\/thead>
Molding Principle<\/td>Solid-state plastic deformation<\/td>Liquid High Pressure Casting<\/td><\/tr>
Minimum wall thickness<\/td>\u22651.0mm<\/td>0.5mm<\/td><\/tr>
Mold cost (typical)<\/td>\u00a550,000 (construction profiles)<\/td>\u00a5800,000 (automobile parts)<\/td><\/tr>
production-ready batch<\/td>500-50,000 pieces<\/td>>10,000 pieces<\/td><\/tr>
surface treatment<\/td>Anodized (cost +15%)<\/td>Powder coating (cost +20%)<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

Frequently Asked Questions (FAQ)<\/strong>\u200b<\/h2>\n\n\n\n

1. When must I choose aluminum extrusion?<\/h3>\n\n\n\n
    \n
  • \u200bRequirement Scenarios<\/strong>Long-size structural parts (>5 meters), anodized parts, and small to medium-sized custom orders.<\/li>\n\n\n\n
  • \u200btypical case<\/strong>: High-speed railroad car keel (tensile strength >310MPa), outdoor billboard frame (weather-resistant life of 10 years +).<\/li>\n<\/ul>\n\n\n\n

    2. Why is die casting better for automotive parts?<\/h3>\n\n\n\n
      \n
    • \u200btechnology adaptability<\/strong>: 30% weight reduction in unibody molding (370 fewer parts in Tesla's rear chassis die casting), with mass production beats of 90 seconds per piece.<\/li>\n\n\n\n
    • \u200bcost threshold<\/strong>: When the order quantity > 50,000 pieces, die-casting unit cost is 40% lower than extrusion (Source: China Society of Automotive Engineering).<\/li>\n<\/ul>\n\n\n\n

      3. What is the essential difference between the surface treatment of the two processes?<\/h3>\n\n\n\n
        \n
      • \u200baluminum extrusion<\/strong>: Dependent on anodizing to form a dense aluminum oxide layer (film thickness 0.01-0.03mm), but wear resistance is only equivalent to 1\/3 of hard anodizing.<\/li>\n\n\n\n
      • \u200baluminum die casting<\/strong>: Due to surface porosity defects, electrophoretic coating (film thickness 20-30\u03bcm) or nano-ceramic coating (cost increase of 25%) is mostly used.<\/li>\n<\/ul>\n\n\n\n

        4. How to solve the problem of porosity in die castings?<\/h3>\n\n\n\n
          \n
        • \u200bProcess upgrades<\/strong>: Adopting vacuum die-casting technology (vacuum degree \u2264 50mbar), the porosity is reduced from 5% to 0.5%.<\/li>\n\n\n\n
        • \u200bMaterial optimization<\/strong>High purity aluminum ingot (Fe content <0.15%) is used in conjunction with rare earth densifiers to enhance melt fluidity.<\/li>\n<\/ul>\n\n\n\n

          5. What are the future trends in technology convergence?<\/h3>\n\n\n\n
            \n
          • \u200bExtrusion-die casting composite process<\/strong>: Extrusion is used to create the main bearing structure, and then complex features are die-cast locally (Toyota's new battery tray costs 18% less).<\/li>\n\n\n\n
          • \u200bSemi-solid molding<\/strong>: Aluminum paste is formed in the solid-liquid coexistence state, combining the strength of extruded parts (tensile 380 MPa) with the complexity of die castings.<\/li>\n<\/ul>","protected":false},"excerpt":{"rendered":"

            As an engineer deeply involved in aluminum alloy forming for more than 20 years, I am often asked about the core differences between aluminum extrusion and aluminum die casting. In this article, I will combine the high-pressure\/low-pressure\/gravity casting practical experience to make a systematic comparison from material science, process principle to business decision. What is aluminum extrusion? Aluminum extrusion is a solid-state process of extruding through a die, belonging to solid-state plastic forming, commonly used in the production of assembly line aluminum profiles, heat dissipation aluminum parts and so on. At its core, aluminum rods heated to a plastic state (400-500\u00b0C) are fed into an extruder and forced through a die of a specific cross-sectional shape to form a continuous profile, which can be used to manufacture long-sized products such as door and window frames, rails, and other long products (longitudinal lengths of up to 10 meters or more). Advantages of Aluminum Extrusion Aluminum extrusion products have lightweight, corrosion-resistant characteristics, lower tooling investment costs ...<\/p>","protected":false},"author":1,"featured_media":1968,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[21],"tags":[69],"class_list":["post-1966","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-about-news","tag-aluminum-alloy-manufacturing-process"],"_links":{"self":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/1966","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/comments?post=1966"}],"version-history":[{"count":0,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/1966\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media\/1968"}],"wp:attachment":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media?parent=1966"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/categories?post=1966"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/tags?post=1966"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}