Aluminum High Pressure Die Casting

Aluminum is the most commonly cast metal. Given its strength and lightweight metal properties it is the go to metal being used today in advanced automotive and industrial applications.

Aluminum die cast parts have advantages over other metals and alloys. It is easier to machine than other materials, lighter in weight, corrosion resistant, highly conductive, and has the right amount of stiffness (a property of a material which is rigid and difficult to bend).  The non-ferrous metal is used largely as an alternate material for light-weighting purposes, weight reduction and a means to saving costs over other materials.

Aluminum die cast parts are used in multiple industries such as; automotive, commercial diesel, agricultural, industrial and consumer goods.

The die casting process is a production process that has high throughput and allows for high volume manufacturing of die cast parts. Tooling is specialized and can range from a simple 1-cavity die to a multi-cavity die, allowing for greater efficiency and parts per hour. Very simple to very complex parts can be produces with this manufacturing method.

Huppert Engineering has been involved with aluminum high pressure die castings for over 25 years and has experience in engineered die cast sales, tooling and production.  Within our product portfolio, we have press sizes that go up to 2,000 tons which allows us to support small and large sized components.

Aluminum alloys produced are 360, 380, 383, 390, 413.  B390 is also an alloy that is very common, and experience is also available with this alloy.

A wide range of products are also possible such as clutch housings, transmission housings, torque transfer case housings, extension housings, front covers, oil pans, cam ladder frames, cyinder head covers, stators, water pumps, gear cases, thrust rods, valve bodies, connecting rods, fuel filters, air compressor manifolds, cooler housings, oil pump housings and sprockets.  

Aluminum Sand Casting and Permanent Mold Casting

Huppert Engineering offers customers aluminum casting that utilize the sand casting and permanent mold casting processes.   Castings sizes range from several pounds to over 50lbs.  Simple and complex geometries can be cast utilizing both processes and simple to complex coring is also available.  With the shell core process, internal passages and openings can be create which can reduce machining and weight.  Currently, there are several castings lines available utilizing Hunter automatic molding machines with different box sizes for the sand cast process.  For permanent mold, Hall Machines are used (Hall Tilters).  Permanent mold equipment allows small to large casting capabilities with a wide variety of complexity.  Robotic finishing is also available for more of an automated process.  Also, castings may flow through a standard finishing cell.  Vertically integrated with heat treatment and CNC machining and assembly.  

Foundry Key Processes and Equipment:

  • Sand Casting: 
    • Hunter 30X32 Automatic Molding Machine
    • Hunter 20X24 Automatic Molding Machine
  • Permanent Mold: 
    • (3) Hall H3 Tilters
    • (1) Hall 6H Tilter
  • Core making: 
    • 12 Shell Core Machines
  • Cleaning/Finishing: 
    • Various Saws and Grinders
    • Robotic Finishing Cell
    • Shot-blasting Equipment
  • Heat Treat: 
    • (1) Drop-bottom Heat Treat Furnace
    • (3) Aging Ovens
  • Inspection: 
    • Spectro-max Spectrometer 
    • Brinell Hardness Tester
    • Tensile Tester

CNC machining and assembly of castings is also available.  Just request a quote and we will review your project quickly!

Aluminum Extrusions

Huppert Engineering has been extensively involved with aluminum extrusions. Huppert offers a fully vertically integrated extrusion supply option with extrusion press lines ranging from 1250 ton up to 5500 ton presses.  Order sizes from range small, to medium, to large volume projects. 

Products include extruded profiles, bent profiles, up to fully fabricated machined profiles.

 Vertical integration includes:

  • Raw Billets processing
    • Ingot raw material converted to 6”, 7”, 8”, 9”, 10” and 14” billets in the form of 6xxx, 1xxx, 7xxx, 9xxx alloy material
  • Mold/Die Production
  • Extrusion Lines
  • Surface Treatment Facilities
    • Anodizing
    • Powder Coating & Sublimation
  • Full Fabrication Facilities

Aluminum extrusions (or profiles) are continuing to see significant growth within many industries.  These industries include:

  • Automotive
  • Construction
  • Railway
  • Commercial Vehicles
  • Energy
  • Aerospace
  • Consumer goods
  • Many more….

Advantages to using aluminum are in many cases numerous.  These advantages include:

  • Lightweight
  • Recyclable
  • Strong
  • Resilient
  • Corrosion-Resistant
  • Electrically Conductive
  • Fabrication
  • Tolerancing
  • Cost-effective
  • Short Lead Times

Please contact us to request a quote or review any projects you may need help with.