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What Is the Difference Between Cast Aluminum and Die-Cast Aluminum?

Nov. 14, 2023

Aluminum CastingMany everyday items are aluminum Casting Foundry.

Casting metal refers to forming by melting and then pouring it into a mold. When the metal cools and solidifies, it adopts the shape of the mold surrounding it, and once it is completely cooled, it can be withdrawn. When they want to make cast aluminum products, manufacturers can choose several methods. One of them is called die casting.


Conversion is a broad term that describes various methods. Die casting is just one of them, although as far as aluminum is concerned, die casting is one of the three most popular. Two other important methods are called permanent molds and sand casting. Die casting can provide very high accuracy and a very consistent shape, while sand casting is more versatile and is better for objects with complex patterns and designs.

Die Casting

In die casting, the manufacturer first melts the aluminum and then presses it into a steel mold under high pressure. The mold is called a mold and is made of alloy tool steel, divided into two or more parts. One of these parts is called the cap half and remains fixed; on the contrary, once the aluminum solidifies, the ejector half is removed, and the final product is discharged at this time. The steel mold quickly conducts heat away from the aluminum, so the cooling process is very rapid.

What is Cast Aluminum?

Cast aluminum is created when aluminum is heated to extremely high temperatures. The molten aluminum is then molded into a shape and cooled to craft a wide variety of products.

To prepare for the manufacturing of cast aluminum parts, the mold must be made with precision because its quality will have a direct impact on the shape and surface finish of the finished aluminum casting.

The mold can be made from many different materials, including tool steel because aluminum has a lower melting point than steel. Another material that a mold can be made out of for aluminum casting is sand. For this, the sand is pressed to take the form of the desired finished part. Once the sand is formed, the liquid aluminum is poured into it and allowed to cool.

Cast aluminum parts have properties similar to other aluminum components. Once the casting process is complete the aluminum castings quickly form an exterior layer of aluminum oxide that helps protect against corrosion.

Commonly used cast aluminum alloys in China include A356, A380, ADC12, etc.

What is Die cast aluminum?

Die cast aluminum is a kind of aluminum wherein metals are molted under high pressure in the mold cavities. In the die casting process, the metals are hardened and the desired shapes are produced. Aluminum die casting can be made with the use of either a hot chamber or cold chamber process.

Aluminum die casting is considered a non-expendable technique that can be repeatedly used to produce different shapes, sizes, and thicknesses of die cast aluminum. The die casting process can produce a variety of shapes with accuracy and attractiveness.

Aluminum die casting is now considered an industrial procedure for the purpose of creating aluminum for sale or made as part of machines or any other commercial or industrial production. This is now the easiest process since aluminum is melted in the designated molds to produce the desired size, shape, and thickness. This process is essential in creating metal parts with specified details and quality.

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In the aluminum die casting process, metals are molten in the cavities of steel molds using a high-pressure technique. Aluminum die casting can be done in a single or multiple cavities, unit die, or a combination of dies depending on what is to be produced.

Before, aluminum die casting is done using a low-pressure injection. However, recently die casting using high pressure is common as it can squeeze die cast aluminum to the desired sizes and shapes.

To produce smooth casting, the metal that is molted is injected under both high pressure and speed. The high pressure is maintained until the metal becomes solid. Once it is hardened, the die cast is opened for the purpose of removing the metal cast.

Aluminum manufacturers used many variations to produce the specified results. They can use any of the following: squeeze casting or semi-solid molding. In squeeze molding, the molten metal is cast without any gas entrapment or turbulence using high pressure for the purpose of achieving high-quality results, dense as well as treatable components of the materials. On the other hand, in semi-solid molding, the metal billets are cast for the purpose of producing heat-treatable aluminum castings with low consistency.

With the advent of modern technology, more sophisticated machines are now used to have consistent quality control. Either cold chamber or hot chamber methods can be used for aluminum die casting. Aluminum die casting is the biggest die casting technique used nowadays to produce commercial, consumer, and industrial products salable in the markets today.

Aluminum die casting is proven beneficial to industrial products. In this process, there are various modifications that can be made to the production. Manufacturers spend less and incur less cost and less time in the making of the produced aluminum which is more attractive to the eyes of the buyers.

Aluminum die casting can totally eliminate post machining and repeated molding. This process is very economical and finished products made under this process are accurate and long-lasting.


Each technology has its advantages. Die casting can be automated and is, therefore, more suitable for mass production, although the initial cost of the equipment is usually higher. For smaller volumes and larger or more complex products, sand casting is more economical. Permanent molds can provide stronger and more durable finished products. Many aluminum objects (such as car parts or cookware) are made through one of these processes.

Our company provides various aluminum casting products, if you are interested in our products, please feel free to contact us.

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