High-Pressure Aluminium Die Casting

Looking for durable, lightweight, and cost-effective components for your industry? At Audhe Industries, we specialise in High-Pressure Aluminium Die Casting to create precise and durable aluminium parts. Whether you're in the automotive, aerospace, or other industries, we deliver custom die castings designed to meet your specific needs.

You can count on us for top-quality results every time. We understand that every business has different requirements, which is why we offer tailored solutions for:

• Precise parts for intricate designs
• Strong components for demanding conditions
• Affordable solutions for high-volume production

No matter your project size or complexity, Audhe Industries is here to provide the right, high-quality solution for your business.

Get in touch with us today to discuss your project needs and receive a custom quote for your next high-performance die-cast part. Our team is ready to support you at every step of the process—from design to production.

Contact Us Now and start building reliable, cost-effective, and durable die-cast components with Audhe Industries!

High-pressure aluminium die casting is a highly efficient manufacturing process where molten aluminium is injected into a metal mould under high pressure. This method creates precise, complex, and high-performance aluminium parts that are strong yet lightweight.

It's widely used for producing high-precision parts with tight tolerances, which is essential for industries such as automotive, aerospace, electronics, and industrial equipment manufacturing.

• Precision and Accuracy: We create our high-pressure die-cast parts with minimal defects and maximum performance.
• Strength and Durability: Aluminium offers lightweight, yet strong components perfect for demanding environments.
• Cost-Effective for High Volumes: Ideal for large-scale production runs, reducing the cost per unit.
• Design Flexibility: Capable of creating complex shapes, thin walls, and intricate details.

At Audhe Industries, we provide custom die casting solutions for the automotive industry. Our strong and durable aluminium parts are perfect for both electric and gas-powered vehicles. Using advanced die-casting, we reduce weight while keeping strength, which improves your vehicle’s performance and safety..

Key Benefits:

• Lightweight and durable automotive components for improved performance
• Enhanced fuel efficiency through lightweight parts
• Increased vehicle safety with high-strength die-cast components
• Precision engineering for complex automotive designs

2. Aerospace Industry: High-Precision Parts for Performance and Safety

In the aerospace sector, precision and lightweight strength are crucial. Every component must meet strict performance standards while maintaining minimal weight. High-pressure aluminium die casting is the perfect solution for producing brackets, mountings, housings, and structural components that must withstand extreme conditions, including high pressure and temperature variations.

Why Choose Audhe Industries for Aerospace Die Casting?

We specialise in making precise die-cast parts for the aerospace industry. From aircraft frames to engine components, our parts reduce weight while staying strong and durable. They help improve fuel efficiency and performance in both commercial aviation and space exploration.

Key Benefits:

• Lightweight yet durable aerospace components for enhanced fuel efficiency
• Precise and high-strength parts for critical applications
• Cost-effective manufacturing for large-scale aerospace production
• Components that comply with stringent aerospace safety standards

3. Electronics Industry: High-Performance and Reliable Enclosures

In the fast-evolving electronics industry, thermal management and protection are paramount. Aluminium die-cast enclosures protect sensitive electronics from heat, impact, and outside elements. Devices like smartphones, laptops, LED housings, and home appliances need enclosures that are both lightweight and durable, while also helping to release heat.

Why Choose Audhe Industries for Electronics Die Casting?

Our high-quality aluminium die-cast enclosures ensure optimal thermal conductivity, providing your electronic devices with enhanced heat dissipation. These enclosures protect your products, improve their performance, and extend their lifespan. Whether you're designing smartphone housings, laptop casings, or LED light enclosures, Audhe Industries has the perfect die-casting solution for your needs.

Key Benefits:

• Enhanced thermal management for heat-sensitive components
• Lightweight and durable enclosures for superior protection
• Environmental protection against moisture, dust, and impact
• Custom designs for complex electronic components

4. Industrial Equipment: Enhancing Machine Efficiency and Durability

Industrial equipment makers need parts that can withstand tough conditions, extreme temperatures, and heavy use. High-pressure die casting is key for making reliable gears, pumps, machine parts, and valves that perform well in challenging environments.

Why Choose Audhe Industries for Industrial Equipment Die Casting?

Our die-casting solutions improve the performance and durability of industrial equipment. We make precise aluminium parts built to resist wear, high heat, and abrasion. By reducing maintenance and extending component lifespan, we help manufacturers boost efficiency and cut downtime.

Key Benefits:

• Enhanced machine efficiency with durable die-cast components
• Reduced maintenance and wear for industrial machinery
• Long-lasting, reliable components for industrial operations
• Custom die-cast parts tailored to your specific industrial needs

At Audhe Industries, we follow a streamlined and precise high pressure aluminium die casting process to deliver high-quality, durable parts. Understanding the process is key to ensuring the right outcomes for your manufacturing needs. Our aluminium die casting process flow chart outlines the steps that guarantee accuracy, consistency, and efficiency.

1. High-Pressure Aluminium Die Casting Mould Preparation: We begin by preparing the die moulds according to the precise specifications for each part, ensuring the highest quality production.
2. Melting the Aluminium: High-quality aluminium alloy is melted in a furnace to reach the optimal pouring temperature, ensuring fluidity and easy mould filling.
3. Injection of Molten Metal: The molten aluminium is injected into the die at high pressure (typically between 800 to 2,500 bar) to ensure complete mould filling and fine details.
4. Cooling and Solidification: Once the molten metal fills the mould, it is cooled quickly, allowing the aluminium to solidify and take its final shape.
5. Ejection of Part: After solidification, the die is opened, and the finished part is ejected.
6. Trimming and Finishing: Any excess material (like flash) is trimmed, and the part undergoes additional finishing steps for smooth surfaces and precise dimensions.
7. Quality Inspection: Every part is carefully inspected to meet high standards of dimensional accuracy and strength, ensuring the part performs well in its intended application.

By following this high pressure aluminium die casting process flow, Audhe Industries ensures that every part, from automotive components to electronic housings, meets the highest quality standards and performs reliably in your industry.

At Audhe Industries, we follow a proven, user-centric die casting process to ensure high-precision results. Here’s how we create the perfect die cast part for your needs:

This process is not just about producing parts—it’s about delivering the exact quality you need to meet your business’s goals. Whether you’re aiming to reduce weight for better fuel efficiency in your vehicles or need components with exceptional strength for aerospace applications, high-pressure aluminium die casting ensures that your parts meet your exact specifications with the reliability you expect.

Step 1: Tool Design and Prototyping

We begin by working closely with you to design a custom die using advanced CAD software. This allows us to create 3D prototypes and ensure that your design will be accurately reproduced in the final casting. Prototyping also helps minimize errors before large-scale production.

Step 2: Aluminium Injection

Once the die is finalized, we inject molten aluminium into the die cavity under high pressure. This process ensures the aluminium fills the mould completely, capturing intricate details and features for a precise, high-quality casting.

Step 3: Cooling and Ejection

After injection, the molten aluminium cools and solidifies. We then carefully eject the finished component, ensuring it retains its shape and strength with minimal waste or defects.

Step 4: Post-Casting Operations

Following the casting process, we conduct post-casting operations such as machining, cleaning, and surface finishing to refine the part’s quality, appearance, and performance.

Defect	Description	Potential Causes	Solutions/Prevention
Porosity	Small air pockets or voids inside the casting, affecting structural integrity.	Inadequate vacuum, gas entrapment, improper mould temperature.	Use vacuum-assisted die casting, optimize mould design and ventilation.
Cold Shuts	Two streams of molten metal that don’t fuse completely, leaving a weak spot.	Low injection speed, poor mould design, cold mould.	Adjust injection speed and temperature, improve mould heating.
Cracks	Surface or internal cracks in the casting, compromising strength and durability.	High cooling rates, excessive pressure, improper alloy choice.	Control cooling rates, optimize pressure and alloy selection.
Misruns	Incomplete filling of the mould cavity, resulting in missing sections of the part.	Insufficient injection pressure, fast cooling.	Increase injection pressure and adjust cooling rates.
Flash	Excess material around the edges of the casting, usually from overfilling the mould.	Excessive injection pressure, poor die alignment.	Optimize pressure, improve die design and alignment.
Shrinkage	Gaps or voids caused by material shrinking as it cools, leading to dimensional inconsistencies.	Insufficient material supply, inadequate cooling.	Adjust mould filling, ensure proper material supply and cooling design.
Surface Imperfections	Visible defects on the casting surface, such as roughness or uneven texture.	Poor mould surface finish, inadequate lubrication.	Improve mould finish, optimize lubrication systems.

At Audhe Industries, we know how important it is to have high-quality, defect-free components. That's why we use vacuum-assisted high-pressure die casting for applications that require smooth surfaces and few defects. This advanced process uses a vacuum during aluminium injection to reduce air pockets, ensuring the final parts are dense, strong, and precise.

Key benefits include:

• Flawless Surface Finish: By eliminating porosity and air bubbles, we achieve a smoother, more polished surface, perfect for critical parts.
• Increased Strength and Durability: The process ensures superior material density, giving your components the strength needed for demanding environments.
• Reduced Defects: Vacuum assistance helps minimize common issues like cold shuts and misruns, ensuring a more consistent and high-quality output.
• Ideal for High-Performance Industries: This technique is especially useful for aerospace, electronics, and other industries where parts need to meet high-performance standards.

Whether you're producing aerospace components, electronic enclosures, or automotive parts, our vacuum-assisted HPDC process guarantees high-quality, reliable aluminium die-cast parts that meet the toughest requirements.

At Audhe Industries, we understand that precision and reliability are crucial for your manufacturing needs. That’s why we offer a high-pressure die casting pressure range from 800 to 2,500 bar, tailored to meet the exact requirements of your projects. Whether you're in automotive manufacturing, aerospace, or consumer electronics, our pressure-controlled die casting process ensures:

Optimal mould filling and high-quality parts: Perfect for intricate and detailed components, reducing the risk of defects. Superior surface finish and durability: Achieved by maintaining precise pressure throughout the process, ideal for industries requiring strong, long-lasting components. Dimensional accuracy: With our consistent pressure range, we deliver parts with minimal variation, meeting the tightest tolerances.

For your high-pressure die casting needs, you can trust Audhe Industries to provide customized die casting solutions with the right pressure range to maximize the performance and quality of your parts. Whether it’s aluminium die casting, zinc die casting, or magnesium casting, our process ensures consistent results for high-volume production.

High-Pressure Aluminium Die Casting (HPDC) plays a critical role in the automotive industry by enhancing vehicle performance through a superior strength-to-weight ratio, improving fuel efficiency, and reducing overall vehicle weight. At Audhe Industries, we specialise in HPDC (High Pressure Die Casting) aluminium alloys that are specifically optimized for automotive applications. Our aluminium die-cast parts for automotive industry offer:

• Superior Durability: High-strength, lightweight aluminium parts, like engine blocks, transmission housings, wheels, and structural components, are built to handle the toughest conditions.
• Enhanced Fuel Efficiency: By reducing vehicle weight with aluminium die casting, we improve fuel economy and drivability, making your vehicles more efficient and eco-friendly.
• Custom Alloy Formulations: We offer tailored aluminium alloys for automotive parts that meet the specific needs of both electric vehicle manufacturing and internal combustion engine vehicles.
• Precision Engineering: Using cutting-edge die casting technology, we guarantee dimensional accuracy and exceptional surface finishes for automotive die-cast components.
• Reduced Maintenance: Our high-quality aluminium automotive parts are designed for long-term durability, reducing maintenance and repair costs over the vehicle’s lifecycle.

Whether you're designing electric vehicles (EVs) or manufacturing traditional gas-powered vehicles, our high-performance aluminium die-cast components provide a cost-effective solution that meets the demanding standards of the automotive sector. From lightweight engine parts to precision transmission housings, Audhe Industries delivers reliable, strong, and fuel-efficient automotive solutions tailored to your needs.

As one of the top high-pressure die casting manufacturers in India, Audhe Industries delivers precise, durable, and cost-effective aluminium components tailored to your business needs. Here’s why you should choose us:

• Expertise: With years of experience, we specialise in high-quality, precision die-cast parts for industries like automotive, aerospace, electronics, and industrial equipment.
• Advanced Technology: We use the latest HPDC and vacuum-assisted die casting techniques to ensure high performance, dimensional accuracy, and minimal defects.
• Customization: We offer tailored solutions for your specific needs, whether it's lightweight automotive parts, high-strength aerospace components, or reliable electronic enclosures.
• Cost-Effective: Our efficient processes provide high-quality results, especially for high-volume production, helping you save on costs without compromising quality.
• Fast Turnaround: We prioritise quick lead times to meet your deadlines while maintaining top-tier quality.

Audhe Industries is your reliable partner for high-precision, affordable die-casting solutions that help your business thrive. Get in touch today to see how we can support your next project!

At Audhe Industries, we understand that even the smallest defect can impact the performance and reliability of your products. Our focus is on ensuring that every aluminium die-cast component meets the highest standards of quality. Some common defects in high pressure die casting include:

• Porosity: Air pockets or voids formed within the material due to trapped gas. This can weaken the structural integrity of the part.
• Cold Shuts: Occurs when molten metal fails to fuse properly during injection, leading to incomplete fills and weak spots.
• Flash: Excess material that forms around the part due to improper mould closure or excess pressure during the injection process.
• Misruns: When the molten metal doesn't completely fill the mould cavity, leaving an incomplete or defective part.
• Warping: When the part distorts or changes shape after solidification, caused by uneven cooling rates.
• Cracking: Structural failure often resulting from residual stresses during the cooling phase or improper alloy choice.
• Inclusions: Foreign particles or contaminants within the die-cast part, which can weaken the component.

To address these potential issues and ensure top-quality die-cast parts, we employ advanced techniques and thorough monitoring during production:

• Vacuum-Assisted Die Casting: This process minimizes air entrapment, reducing porosity and improving the density of the parts, ensuring stronger and more reliable components.
• Optimized Mould Design and Maintenance: Our engineers work on precise mould designs and perform regular maintenance to prevent flash and cold shuts.
• High-Pressure Injection: We apply the right pressure levels to ensure complete filling of the mould cavity, reducing the risk of misruns and enhancing the final product's precision.
• Controlled Cooling Rates: To prevent warping and cracking, we carefully control the cooling process and ensure uniform cooling across the component.
• Alloy Selection and Quality Control: By selecting the right aluminium alloys tailored for high pressure die casting, we ensure optimal performance and strength. Our stringent material checks prevent inclusions and ensure superior mechanical properties.
• Post-Casting Operations: We perform additional processes such as machining, trimming, and polishing to correct any post-casting defects, improving the surface finish and overall performance of the part.

We conduct thorough defect analysis through our aluminium high pressure die casting defects analysis chart to monitor and minimize defects at every stage of production. By closely monitoring and controlling our processes, we ensure that every component meets stringent quality standards, delivering superior and reliable aluminium parts for your needs.

If you're looking for reliable high-precision aluminium die casting services, Audhe Industries is here to help. Whether you need a single prototype or require a full-scale production run, we offer the most cost-effective, high-quality die casting solutions to meet your business needs.

Contact us today for a free consultation and get a custom quote for your next project. Discover how high-pressure aluminium die casting can boost the quality, durability, and performance of your products.

Related Services:

• Zinc Die Casting: Explore our zinc die casting services for creating durable, lightweight parts for various industries.
• CNC Machining Services: Enhance your die-cast parts with precision CNC machining for exact finishing and intricate details.
• Investment Casting: For even more complex designs, our investment casting services offer unparalleled accuracy and versatility.

At Audhe Industries, we provide high-quality, custom aluminium die casting solutions for industries like automotive, aerospace, electronics, and manufacturing. Focused on precision, cost-efficiency, and fast turnaround, we are your trusted partner for all your high-pressure die casting needs.

For reliable, high-precision die casting, trust Audhe Industries. Contact us today to get started with your next project and experience the benefits of high-performance die cast parts for your business.

Whether you are scaling up production or designing a one-off prototype, Audhe Industries is here to be your trusted partner in delivering high-performance, cost-effective die-cast components. We prioritise your needs to ensure your business runs smoothly and your products exceed expectations.

1. What is the difference between HPDC and LPDC?

The main difference between HPDC (High Pressure Die Casting) and LPDC (Low Pressure Die Casting) is the pressure used during casting. In HPDC, molten metal is injected at high pressure (over 10,000 psi), allowing for fast cooling and precise, small parts—ideal for mass production. In LPDC, lower pressure (1-10 psi) is used, which leads to slower cooling and is better for larger, thicker parts with complex shapes.

2. What is the pressure of HPDC casting?

The pressure used in HPDC casting typically ranges from 10,000 psi to 20,000 psi (689-1379 bar). This high pressure ensures fast filling and precise replication of complex mould cavities, producing high-quality, durable cast parts.

3. What material is an HPDC tool?

HPDC tools are usually made from strong tool steels like H13 or P20, which can handle the high pressures and temperatures in the casting process. These materials provide great wear resistance, thermal stability, and durability, helping the tools last longer.

4. What PSI is needed for pressure casting?

For pressure casting, the required PSI depends on the specific casting method. In HPDC, the pressure is typically between 10,000 psi and 20,000 psi, while in LPDC, the pressure is much lower, around 1-10 psi. The high PSI in HPDC helps achieve high precision and faster cycle times.

5. What is the flow of the HPDC process?

The flow of the HPDC process involves several key steps:

1. Mould Preparation: The mould is heated and lubricated to ensure smooth casting and easy removal.
2. Injection: Molten metal is injected into the mould at high pressure, filling the mould cavity in milliseconds.
3. Cooling: The metal cools and solidifies rapidly within the mould, forming the desired shape.
4. Ejection: Once cooled, the cast part is ejected from the mould.
5. Finishing: The part undergoes any necessary finishing processes such as trimming, machining, or surface treatment.

6. What is the process of high pressure moulding?

High pressure moulding (or HPDC) is a casting process where molten metal is injected into a mould under very high pressure. The process begins by preparing a metal mould, followed by heating and lubricating it. Molten metal is then forced into the mould cavity, and the pressure ensures that the mould is completely filled, producing a precise part. After the metal cools, the part is ejected from the mould, ready for any finishing work.

7. What are the different types of HPDC?

There are several types of HPDC processes, including:

• Cold Chamber HPDC: The molten metal is poured into a chamber before being injected into the mould. This method is used for metals with high melting points, such as aluminium, magnesium, and copper alloys.
• Hot Chamber HPDC: The metal is injected directly from a furnace into the mould, making it ideal for low-melting-point metals like zinc and lead-based alloys.
• Vacuum HPDC: A vacuum is applied to remove air from the mould, improving the quality and surface finish of the cast part.
• Die Casting with In-Mould Coating: The mould is pre-coated with a layer of material to improve the surface finish and reduce defects.

8.How can I ensure the parts will meet my design requirements?

Our engineers work with you throughout the design and prototyping stages to ensure that the final die-cast parts meet your exact specifications. We offer rapid prototyping and continuous feedback to minimize errors and ensure a perfect final product.

9.How do I know if die casting is the right method for my project?

If you're dealing with complex designs, high-volume production, or need parts with exceptional strength-to-weight ratios, high-pressure aluminium die casting is the ideal solution. Our team will assess your needs and recommend the most cost-effective and efficient approach.