From 6061 to ADC12: Challenges and Solutions In Material Selection for Die Casting Components

Table of Contents

• 6061 Aluminium as a Die Casting Alloy-Strengths and Challenges

-Strengths of 6061 Aluminium

-Limitations of 6061 Aluminium

• Aluminium ADC12 as a Die Casting Alloy-Strengths and Challenges

-Strengths

-Challenges

• Why ADC 12 is Being Preferred Over 6061-The Reasons Behind Transition
• Conclusion
• References

Meta Description

Explore the transition in die-casting materials from Aluminum 6061 to Aluminum ADC12, revealing how ADC12's superior fluidity and performance in complex shapes are reshaping industry standards. Discover the strengths and challenges of each alloy, and why ADC12 is increasingly preferred in automotive, aerospace, and electronics manufacturing.

Main Body

When it comes to manufacturing of intricate metallic parts to be used in a variety of industries, die casting?has emerged as one of the most commonly used manufacturing processes. It helps make complex metallic parts in all sizes and shapes by melting the metal?alloys under high pressure and then pouring them into a pre-made mold to be solidified in the required shape.

However, for die-casting?to be successful there are a few criteria to be met. One of the most important considerations in die-casting?is the selection of appropriate material. The material selected for die casting is mostly an alloy made specifically?to combine a few highly in-demand traits like

• Strength to weight ratio
• Fluidity
• Heat resistance
• Corrosion resistance.

Two of the most commonly relied upon alloys today for die casting are Aluminum 6061 and Aluminium ADC12. ?However, although Aluminium 6061 is being used since years and years for a combination of some highly desirable traits, Aluminium ADC12 emerged as a more popular choice in recent years.

Let us have a look at how the latter is offering an even more suitable combination of the required traits as compared to the 6061 variation and hence taking over as a more commonly used alloy variety.

Aluminium 6061-Strengths and Challenges

Aluminium 6061 is a combination of silicon, aluminium, copper, and a number of other elements in a specific proportion. It is this set ratio of different elements that give this alloy its characteristic properties.

Strengths of 6061 Aluminium

Aluminium 6061 finds its applications in those industries that call for high-strength and lightweight material. Made with aluminum, magnesium, chromium, copper, and silicone, this alloy has a few desirable properties to offer, making it a good choice for some specific industries. It offers the following positives:

• Aluminium 6061 is highly corrosion resistant which makes it an ideal material to be used in automotive as well as aerospace, rail transit, and shipbuilding.
• It also has high electrical conductivity making it a preferred choice for electronic device manufacturing.

Limitations of 6061 Aluminium

Although it has a good weight to strength ratio and is high resistance to corrosion, aluminium 6061 poses a few serious challenges limiting its uses as an ideal die cast material. Some of the areas that have acted as an impediment to the use of 6061 in different areas and given way to other alloys like aluminium ADC12 as a more preferred choice are as follows:

• Aluminium 6061 has comparatively bad weldability.
• It is not very heat resistant, hence it is not an ideal choice for industries where exposure to high temperatures is a concern.
• Although it does offer some decent strength, it still isn’t among the strongest of alloys out there. 6061 as compared to alloys like ADC12 has lower strength.
• One of the biggest disadvantages associated with 6061 is that it has low fluidity. This means it cannot adapt fully to the molds with intricate details in shape. The products that need to have complex shapes with thin walls cannot be made with perfection using aluminium 6061.

Aluminium ADC12 as a Die Casting Alloy-Strengths and Challenges

Aluminium ADC 12 is a relatively advanced variation in aluminium alloys. It has a unique combination of materials and it features a higher silicone percentage compared to many other aluminium alloys.

Strengths

The higher silicone percentage in aluminium ADC 12 makes it an idea choice to be used in a wide range of products. Its unique composition makes ADC 12 an alloy with a number of unmatched strengths. Some of those are as under:

• One of its greatest strengths is that aluminium ADC 12 has great fluidity. This means it can fill the molds completely and can flow evenly to even the most complex and intricate parts of a mold. Hence, with ADC 12, complex geometric shapes are possible.
• Its resistance to corrosion makes ADC 12 an appropriate choice for making automotive parts, shipping parts, aerospace, and a number of other products.
• High electric conductivity exhibited by aluminium ADC 12 means it is a good material to be used for making electronic equipment.

Challenges

The only biggest concern while using ADC 12 as a die casting material is the risk of hot cracking. In some thicker, denser parts, the final product may crack during the cooling process, as the melted allow starts solidifying. However, this problem has been addressed by grain refinement and adjusting the percentage of different components to make sure, the risk of hot cracking can be refined significantly.

Why ADC 12 is Being Preferred Over 6061-The Reasons Behind Transition

Almost all industries where aluminium 6061 was once used widely as a preferred die casting material are now preferring ADC 12 as a better choice. This transition has a number of factors behind it. For example:

• ADC 12 offers much better fluidity as compared to 6061 and hence the former is a perfect substitution for the latter when the high strength also needs to be combined with better fluidity due to complex shapes. This is because the ADC 12 allows better results with the products that will have thinner walls.
• ADC 12 is among the cheapest aluminium alloys available in the market and yet have a decent strength-to-weight ratio and high resistance to corrosion. Hence, it is an ideal choice for varying industries.

In short, ADC 12 provides better results whether it is the final finish or accurate shapes as compared to 6061 and is hence being preferred by manufacturers.

Conclusion

In conclusion, the evolution in die casting material preferences from Aluminum 6061 to Aluminum ADC12 underscores a shift towards alloys offering superior fluidity and performance in complex shapes.

While Aluminum 6061 remains valuable for its corrosion resistance and strength-to-weight ratio, its limitations in weldability, heat resistance, and fluidity have paved the way for ADC12.

With its enhanced fluidity and competitive cost, ADC12 emerges as a versatile choice across industries including automotive, aerospace, and electronics. This transition highlights the industry's continuous quest for materials that deliver both strength and manufacturing efficiency in intricate die-cast components.

References

• https://en.wikipedia.org/wiki/Die_casting
• https://www.dynacast.com/en/knowledge-center/blog/8-die-casting-defects-and-how-to-overcome-them#:~:text=Cracks%20are%20fractures%20or%20separations,timing%2C%20and%20enhancing%20thermal%20management.
• https://art-tangent.com/product-category/cnc-machine-processing-machining/
• https://art-tangent.com/product/customized-punching-stamping-for-battery-components/