Manufacturing Process
The Aluminium Die Casting
Process, Step by Step
Twelve controlled stages turn aluminium ingot into an inspected, machined component. Here is what happens at each one — and why it matters for your part.
Live Process // HPDC Cell
One die casting cycle, animated
The core of the process — from the holding furnace to an inspected casting — runs in seconds on each cell.
Stage 01
Melt & Hold
Certified ingots melted and held in Silcarb furnaces at 685°C ± 5°C.
Stage 02
Ladle Transfer
Degassed alloy metered by ladle into the cold-chamber shot sleeve.
Stage 03
High-Pressure Injection
The plunger drives molten aluminium into the clamped steel die.
Stage 04
Solidify & Cool
Die cooling channels set a fine, repeatable microstructure.
Stage 05
Die Open & Eject
Robotic extraction lifts the near-net-shape casting out of the die.
Stage 06
Trim & Inspect
Runner cutting, then CMM and X-ray checks before DOL dispatch.
- Melt:
- 685°C
- Clamp:
- 250T – 350T
- Alloys:
- ADC12 / A380
- Inspection:
- CMM · X-ray
From ingot to dispatch
01
Die design
The die is designed around your part and our machine: parting line, gate and runner layout, overflows and vents to evacuate air, cooling channels to balance die temperature, and ejector pin positions. Slides are added for undercuts. Good gating moves porosity away from machined and pressure-tight areas.
Tool & die development02
Melting
Certified aluminium alloy ingots, plus controlled in-house returns, are melted and held in Silcarb recrystallised silicon-carbide furnaces. Holding temperature is controlled at 685°C ± 5°C with PID control and dual thermocouples — too cold causes cold shuts, too hot increases oxidation and gas pick-up.
03
Alloy handling & degassing
Before transfer, a rotary graphite impeller purges the melt with argon or nitrogen to remove dissolved hydrogen, and flux treatment removes oxides and dross. Chemistry is verified by spectrometer per heat. Clean, degassed metal is the first defence against gas porosity.
04
Injection
A metered dose of metal is ladled into the shot sleeve of a cold-chamber machine. The plunger advances slowly to push air ahead of the metal, then fast to fill the cavity in milliseconds, followed by intensification pressure to compact the metal as it solidifies.
HPDC process in detail05
Solidification
Heat flows into the die steel and out through the cooling channels. Dwell time is set for the thickest section so the part is solid before ejection; die spray between shots controls die temperature and lubricates the surface.
06
Ejection & trimming
The die opens and the casting is extracted. Biscuit, runners and overflows are removed on band saws and abrasive cutting machines, and flash is trimmed.
07
Shot blasting & finishing
Castings are shot blasted for a clean, uniform surface, then vibratory deburred or belt linished as specified. Visible parting lines are blended for cosmetic parts.
Shot blasting & surface finishing08
CNC machining
Faces, bores and threads are machined on fixtures that locate on agreed cast datums. Multi-spindle drilling and tapping handles high-volume hole preparation.
CNC machining of castings09
Coating (where specified)
[INSERT — powder coating / painting / impregnation: in-house, via approved partner, or not offered].
10
Inspection
Dimensional, visual and functional checks (such as leak testing) are performed per the control plan, with CMM layout inspection for first articles and periodic audits.
Quality assurance11
Packing
Parts are cleaned and packed to protect machined faces, in packaging agreed with the customer — [INSERT PACKING OPTIONS, e.g. returnable bins, VCI bags, cartons].
12
Dispatch
Batches are labelled for traceability and dispatched from Thirumudivakkam. Our location gives short transit to the Oragadam and Sriperumbudur automotive hubs; parts can be supplied Direct On Line to assembly.
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Manufacturing Consultation
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Share your drawing and we will propose the route — casting, finishing, machining and inspection — with a quotation.