Aluminium is the most abundant metal of all, as it makes up 8% of the Earth’s crust, and its non-magnetic and ductile properties allow it to have a wide range of applications. One of these applications is within alloys, with the most popular combinations including materials such as copper, zinc and magnesium. Aluminium alloys are created via the die casting process in order to improve the properties of the metal, mainly to increase its strength, since pure aluminium is relatively soft.


Aluminium is the lightest metal with a specific mass of 2700 kg/m3, approximately a third of the density of steel, copper and brass, making it ideal for industries where weight is a crucial consideration – and where reducing product weight helps towards energy efficiency and a smaller carbon footprint.

Based on the type of element aluminium is alloyed with, the alloys can be split into eight categories with aluminium casting:

1xxx Series: no alloying elements, with 90% or more of pure aluminium; the remaining percentage is impurities

2xxx Series: the alloying material is copper, which produces a high strength alloy

3xxx Series: manganese is the alloying element and adds moderate strength and good formability to the alloy

4xxx Series: the alloying element is silicon, which contributes to good aluminium casting properties

5xxx Series: magnesium is added, which creates an alloy that’s highly resistant to corrosion

6xxx Series: with both magnesium and silicon as alloying elements, this category produces alloys that are easily anodised

7xxx Series: zinc is added to this category, creating the strongest alloy of the series

8xxx Series: other elements are added


Aluminium alloys are used in many different industries, sectors and products, such as aerospace, automotive, military, transportation, packaging, food preparation and electrical components. Each aluminium alloy has its own specific properties, so it is vital that you choose the one that best suits your needs and your project’s requirements. Still, the different alloys created via the aluminium casting process have some aspects in common:

  • Lightness
  • Resistance to corrosion
  • High levels of strength
  • Electrical and thermal conductivity
  • Suitable for surface treatments
  • Recyclable

The natural properties of aluminium make it perfect for a broad range of applications. For this reason, high-quality aluminium alloys are highly sought-after for people looking for increasingly innovative processes. At Dean Group, we can create any part you wish from aluminium alloys, through our investment casting process.

Contact Dean Group International for Aluminium Die Casting Services

If you require good mechanical strength parts with high integrity and a gas-tight structure, we can offer investment casting through our ELITE process at our manufacturing facility in Manchester. We can also offer die casting and forging from our supply partners.