Differences Between Aluminum Die Casting and Other Casting Processes: Comprehensive Comparison of Application Scenarios + Performance Differences

Differences Between Aluminum Die Casting and Other Casting Processes: Comprehensive Comparison of Application Scenarios + Performance Differences

In the field of aluminum product forming, aluminum die casting, sand casting, gravity casting, and low-pressure casting are the four most commonly used processes. Different processes vary significantly in forming efficiency, product performance, and cost control, which directly determine their suitable industry scenarios. Many purchasers and manufacturing enterprises easily confuse the selection criteria of various processes. This article will conduct a comprehensive comparison between aluminum die casting and other mainstream casting processes from two core dimensions: performance differences and application scenarios, to assist in accurate selection.

Performance difference is the core of process differentiation. Aluminum die casting relies on high-pressure and high-speed forming, resulting in products with high dimensional accuracy (tolerance up to ±0.05mm) and good surface finish, without the need for complex post-processing; however, due to the high forming speed, gas is easily entrained, leading to many internal pores, medium mechanical properties, and a tensile strength of approximately 200-300MPa. Sand casting has a simple process, with loose internal structure, low accuracy (tolerance ±1-2mm), and rough surface, requiring a lot of post-processing, but it can cast large parts with complex shapes at extremely low cost.

Gravity casting relies on the self-gravity of aluminum melt to fill the cavity, with few internal pores, high density, and mechanical properties superior to die casting (tensile strength 300-400MPa), and medium accuracy (tolerance ±0.5-1mm); however, its forming efficiency is low, making it unsuitable for mass production. Low-pressure casting adopts low-pressure and slow filling, combining high accuracy and high density, with the best mechanical properties comparable to forged parts, but it requires large equipment investment, long production cycle, and high cost.

Application scenarios are accurately divided according to performance differences. Aluminum die casting is suitable for mass production of high-precision thin-walled parts such as auto parts and electronic casings; sand casting is suitable for low-cost, large-size rough parts such as construction machinery bases and large machine tool beds; gravity casting is mostly used for medium-batch products with certain mechanical performance requirements such as engine blocks and wheel hubs; low-pressure casting focuses on high-end precision scenarios such as aerospace components and high-end auto wheel hubs. When selecting a process, it is necessary to comprehensively balance production volume, accuracy, and performance requirements to achieve the optimal match between cost and quality.