Die Designing Casting


GAL Aluminium Extrusion

design department is fully supported with latest version of Auto Cad and other related simulation software where the designed dies can be virtually visualized with their fatigue / flow patterns / support zones and corrected at the initial stages, resulting in early success of dies during trail and ensuring on-time delivery.

A die is the tool shape that the aluminium is pushed through to create the profile. Dies are made of tool steel (normally sis 2242). The die aperture, which corresponds to the desired cross section of the profile, is produced by spark erosion.

There are two main classes of profile – solid and hollow

✔ Solid profiles are produced using a flat, disc-shaped die.

✔ Hollow profiles are produced using a two-part die. In hollow dies, the mandrel (the part that shapes the cavity in the profile), is supported on a bridge. During extrusion, the metal separates around the bridge. The other part of the die shapes the outer contour of the profile.

Large and medium-sized profiles are pressed through a die with only one aperture. Smaller profiles can be advantageously pressed through multi-apertured dies – there may be as many as 16 apertures.

Die lifetime depends on the shape and desired surface quality of the profile.

Die Casting

Casting is a manufacturing process by which liquid or molten metal under high pressure, is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.

The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.

Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are (for example)epoxy, concrete, plaster and clay. It is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys.


Depending on the type of metal being cast, a hot- or cold-chamber machine is used. There are two basic types of die casting machines:

✔ Hot-chamber machines

✔ Cold-chamber machines

These are rated by how much clamping force they can apply.