Process Overview
Low-pressure die casting (LPDC) is the preferred process when you need aluminum components that are both lightweight and structurally reliable. Unlike gravity casting, LPDC uses controlled gas pressure (0.02–0.1 MPa) to push molten aluminum upward into a permanent steel die. The slow, laminar fill eliminates the turbulence that causes gas porosity in conventional casting — the number one failure mode in structural aluminum parts. The result is a dense, homogeneous microstructure that responds well to T5 and T6 heat treatment, achieving tensile strengths of 250–310 MPa. This is why LPDC has become the dominant process for EV battery housings, wheel hubs, and rail transit structural frames. Our engineering team reviews every LPDC drawing for wall thickness transitions, gate placement, and solidification sequence before quoting.
Key Advantages
- Controlled laminar fill eliminates gas porosity — internal density superior to gravity casting
- Heat-treatable to T5/T6 — tensile strength 250–310 MPa achievable in A356/A357
- CT6–CT7 dimensional tolerance — consistent across production runs of 500 to 50,000+ pieces
- Ideal for medium-to-large aluminum components: 0.5kg to 80kg weight range
- Permanent die tooling amortized over long runs — lower per-part cost than sand casting
- Scrap rate typically under 2% with optimized gating and solidification design
Technical Specifications
Process Flow
Step-by-step overview of our Low-Pressure Die Casting workflow — from raw material to finished casting.
Typical Applications
Compatible Materials
Full Technical Specifications
Comprehensive process parameters for Low-Pressure Die Casting — based on ISO 8062 / GB/T 6414 standards.
| Parameter | Value / Range | Notes |
|---|---|---|
| Tolerance Grade (ISO 8062) | CT6 – CT7 | Consistent across production runs |
| Dimensional Tolerance | ±0.3 mm – ±0.5 mm | Depends on part size and die condition |
| Surface Roughness (Ra) | 3.2 – 6.3 μm | As-cast; improved with shot blasting |
| Minimum Wall Thickness | 3.0 mm | Thinner walls with optimised fill pressure |
| Typical Weight Range | 0.5 kg – 80 kg | Larger parts up to 150 kg on request |
| Typical Materials | A356, A357, AlSi7Mg, AlSi9Mg, AlSi12 | All heat-treatable to T5/T6 |
| Typical Applications | EV battery housings, wheel hubs, motor housings, rail structural frames | — |
| Heat Treatment | T5 (artificial aging), T6 (solution + aging) | Tensile strength 250–310 MPa achievable |
| Porosity Control | Internal density ≥ 99.5% | X-ray inspection per ASTM E505 |
| NDT / Inspection | X-ray, CMM dimensional report, tensile test coupons | Third-party available |
| Lead Time (tooling) | 30 – 50 working days | Permanent steel die fabrication |
| Lead Time (production) | 20 – 35 working days | After tooling approval |
* All values are indicative. Actual achievable parameters depend on part geometry, alloy, and tooling design. Contact our engineers for drawing-specific assessment.