The 2024 Fraser of Allander Institute (Strathclyde University) report states that:
“The UK aluminium industry plays a pivotal role in the nation’s manufacturing sector and broader economy. As the UK shifts towards a more sustainable and circular economy, the strategic value of aluminium is expected to grow, owing to its diverse applications and recyclability.”
The report also finds that:
- The wider aluminium industry supports the employment of 108,000 FTE jobs across the UK and the contribution of £9.4 billion in GVA to the UK economy.
- The aluminium production sector supports the employment of 16,500 FTE jobs across the UK and the contribution of £1.9 billion in GVA to the UK economy
- The aluminium production sector has seen an 88% reduction in GHG emissions since 2005 and an 8% reduction since 2015
Within the wider aluminium industry aluminium die casting is a popular manufacturing process involving the pouring or injection of molten aluminium into a mould cavity to produce a strong but light high quality metal component or product.
In the UK, industries for example serving the automotive and aerospace sectors, along with consumer goods, rely on aluminium castings including high pressure casting to produce complex forms with tolerances as low as +/- .05mm.
What is Aluminium Die Casting?
Aluminium die casting is a manufacturing process wherein molten aluminium alloys are poured or injected under pressure into a mould. For high pressure aluminium casting the mould is made from special steels such as H13, a chromium, molybdenum, vanadium “hot work” tool steel characterized by high hardenability and excellent toughness. The hardness of H13 resists thermal fatigue cracking which occurs as a result of cyclic heating and cooling cycles as aluminium is injected under pressure into the mould. Aluminium and aluminium/zinc alloys are injected at temperatures of 500-750 degrees centigrade and modern high-pressure die casting machines can now operate at pressures up to 100MPa/14500psi with locking forces of 2000 tonnes.
Tool steel moulds have relatively long lives (50-100,000 castings) and should be seen as being in the nature of capital investment for the production of aluminium die cast components or products having good mechanical properties with light weight and good resistance to corrosion. Aluminium/zinc alloys can produce castings with mechanical properties such as tensile and yield strengths close to those of mild steel whilst being easily castable. For specific applications Hallam can develop alloys with special mechanical properties or characteristics (e.g. ductility) and supply in volume.
Applications of Aluminium Die Casting
The scope for the application of aluminium die casting is immense and components cast from aluminium alloys are supplied to a broad range of manufacturing sectors. Hallam’s own portfolio of components and products ranges from automotive components, including electric motor housings for EMVs, to lighting system housings, components for medical equipment, and portlights for ocean-going yachts.
The automotive sector alone requires large volumes of die-cast aluminium engine blocks, transmission casings, wheels, heat exchangers and other vital components. The lightweight properties of aluminium alloys make them perfect for increasing fuel or power efficiency in vehicles without compromising structural strengths.
Aluminium die castings are also utilised in the electronics and telecommunication industries for components such as heat sinks and enclosures for the cooling of electronic devices. Aluminium die castings are also vital for use in the aerospace industry, where reduction of weight is crucial without significant loss of strength.
Why Choose Aluminium Die Cast Material?
One of the most important factors that makes aluminium die-cast material preferable to other metals is the excellent weight-to-strength ratio. It also offers superior heat dissipation, corrosion resistance and electrical conductivity and hence can be used for a wide array of applications. Aluminium alloys are also readily machinable.
In terms of process, aluminium die casting can produce complex components to narrow tolerances on a long term repeatable basis and is often introduced to replace other less qualitatively satisfactory processes (e.g. fabrication) or machining from a solid block of material, yielding huge cost savings.
Cast aluminium alloys are also totally recyclable. Aluminium castings and all process-extraneous materials can be repurposed to minimise carbon and environmental footprints.
Why Choose Hallam for Aluminium Die Casting?
The right partner for the of aluminium die cast components and products should have extensive experience in this complex manufacturing field where potential production benefits for the OEM are substantial. Whatever the production requirement it is likely that Hallam, founded in 1968, will have experience of manufacturing a similar cast aluminium alloy component or product, including machining, finishing, assembly or component sourcing requirements. Where new research is required Hallam’s links to the University of Sheffield Advance Manufacturing Research Centre (AMRC), an innovation “Catapult” centre, can be brought to bear.
Conclusion
Aluminium die casting is an indispensable process in today’s manufacturing world, generating high-quality, long-lasting components and products for a wide range of industrial sectors. Lightweight yet strong, die-cast aluminium remains state-of-the art in a wide range of industries, including automotive, electronics, aerospace and medicine. If you need high quality aluminium die-cast components, assemblies or finished products, Hallam would be delighted to help develop your product or re-source your production requirements. Hallam’s commitment to innovation, sustainability, and customer satisfaction through an optimised value proposition sets us apart in the field of aluminium casting.
Please contact Hallam on 01405 813006 option 1 or 07983315292 (Rob Pickersgill, Director), or via our website Realchat facility, to discuss your requirements.
