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  • Aluminum die casting is a process where molten aluminum alloy is injected into a casting die under high pressure and at a controlled temperature. The mold has two sections, the “cover” half and the “ejector” half.
  • Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies).
  •  Most die castings are made from nonferrous metals, specifically zinc, copper, aluminum, magnesium, lead, and tin based alloys, but ferrous metal die castings are possible.


  • Aluminum is one of the few metals that can be cast by all of the processes used in casting metals.
  • The aluminum die casting process makes component parts, decorative trim, and finished products.
  • These processes, in decreasing order of amount of aluminum casting, are: die casting, permanent mold casting, sand casting (green sand and dry sand), plaster casting, investment casting, and continuous casting.


  • The die casting industry continues to be an important supplier to original equipment manufacturers (OEMs) around the world.
  • Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption.
  • Today’s aluminium foundries operate under several needs.


  • Some of the more typical applications for aluminum die castings are enclosures for the electronics industry, hand and power tools, hardware applications, pump parts, plumbing parts, parts for the automotive industries, sports and leisure, home appliances, and communications.
  • The die casting process provides complex metallic shapes within closer tolerances than any other mass production processes.

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