Industry Overview
Pressure die casting is a high-volume manufacturing process particularly suited to producing relatively small, intricate metal components in large quantities. Aluminium pressure die casting is widely used because it enables rapid production of near-net-shaped components with close dimensional control, good surface finish, and thin walls. Aluminium die-cast parts may weigh up to around 5 kilograms.
The process involves injecting molten aluminium alloy under high pressure into a steel die, where it rapidly solidifies before the component is automatically extracted. The method can provide lower production costs and economical manufacturing volumes ranging from thousands to millions of components before die replacement is required.
Different aluminium alloys offer specific characteristics for die casting applications. The report covers the K-alloy, Alloy 413, Alloy 383, Alloy B390, A360, A413, and A380, with properties including corrosion resistance, fluidity, dimensional stability, wear resistance, hardness, pressure tightness, and mechanical or thermal performance. Applications include electrical, electronic, mechanical, domestic, and industrial components, as well as selected automotive, aerospace, and defence applications where mechanical properties and durability are important.
The report proposes a feasibility study for installing a 900Tons/Year Pressure Die Casting (Aluminium) production facility as a Green Field Project.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 3 MT/Day |
| Land & Building (5360 sq.mt.) | Rs. 4.86 Cr |
| Plant & Machinery | Rs. 9.97 Cr |
| Working Capital for 1 Month | Rs. 2.31 Cr |
| Total Capital Investment | Rs. 17.97 Cr |
| Rate of Return | 27% |
| Break Even Point | 58% |
Content Index
- INTRODUCTION
- TYPES OF PRESSURE DIE CASTING
- USES/APPLICATIONS
- BIS SPECIFICATION
- PRESSURE DIE CASTING PROCESS
- PROCESS CYCLE
- PRESSURE DIE CASTING MACHINE AND EQUIPMENTS
- SUPPLIERS OF ALUMINIUM PRESSURE DI-CASTING
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERY
- MARKET OVERVIEW
- ENGINEERING DESIGN CONSIDERATIONS
- ETP FACILITY
- SEWAGE AND WASTE WATER EFFLUENT
- WASTE GENERATION & MANAGEMENT/GREEN BELT
- UTILITIES PER MONTH (ESTIMATED)
- PRINCIPLES OF PLANT LAYOUT
- PLANT LOCATION FACTORS
- HEALTH SAFETY AND ENVIRONMENT
- ANTICIPATED ENVIRONMENTAL IMPACTS
- MITIGATION MEASURES (PROPOSED)
- HSE REQUIREMENT
- PROPOSED IMPLEMENTATION SCHEDULE
- PROJECT FINANCIALS
- PRELIMINARY LAYOUT
- CONCLUSIONS
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Aluminium pressure die casting is a high-pressure manufacturing process in which molten aluminium alloy is injected into a steel mold to produce a shaped component.
The metal solidifies rapidly inside the die and is then extracted, making the process suitable for high-volume production. It is particularly useful for components requiring close dimensional control, good surface finish, thin walls, and relatively intricate designs.
The main advantages are high production rates, economical large-volume manufacturing, dimensional accuracy, good surface finish, and the ability to produce thin-walled components.
Pressure die casting can reduce manufacturing costs compared with other processes when production volumes are sufficiently high. The rapid solidification and repeatable die-based process also support consistent component production, while thin walls can help reduce component weight.
The report identifies seven aluminium alloys or alloy designations for die casting: K-alloy, Alloy 413, Alloy 383, Alloy B390, A360, A413, and A380.
These alloys provide different combinations of properties. Depending on the grade, relevant characteristics include corrosion resistance, fluidity, pressure tightness, dimensional stability, wear resistance, hardness, mechanical properties, thermal performance, and elevated-temperature strength. Alloy selection should therefore be matched to the component's design and operating requirements.
Aluminium pressure die casting is used to manufacture a wide range of electrical, electronic, mechanical, domestic, and industrial components.
The process is also applicable to selected automotive, aerospace, and defence components where appropriate design and casting practices are used. The report specifically notes applications involving hydraulic cylinder components and internal combustion engine pistons for relevant alloy grades. Suitability depends on required mechanical properties, durability, geometry, operating conditions, and production volume.
Pressure die casting is suitable for high-volume production because the process is rapid, repeatable, and capable of producing near-net-shaped components with limited finishing requirements.
A steel die can be used repeatedly for the production of large numbers of components, while automated extraction and rapid metal solidification support short production cycles. These characteristics make the process particularly economical when demand is high enough to justify the required tooling and equipment investment.
A pressure die casting facility should consider process requirements, equipment selection, plant layout, utilities, environmental controls, safety, raw-material handling, and location factors.
The report includes engineering design considerations, pressure die casting machines and equipment, ETP facilities, sewage and wastewater management, waste generation and management, utilities, plant layout principles, plant location factors, and health, safety, and environmental requirements. These elements should be coordinated to support efficient production and responsible facility operation.
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