The Difference between Cold-forged and Die-cast Aluminum Used in LED Luminaire

Both cold-forged aluminum and die-cast aluminum have their unique advantages and limitations when making LED lighting fixtures.

Their differences are mainly reflected in the following aspects:

  1. Different production processes: Cold-forged aluminum is formed by heating the aluminum to a certain temperature and then using a press to forge it. Die-cast aluminum injects molten aluminum into a mold and solidifies it under high pressure.
  2. Different material properties: Cold-forged aluminum has high strength and hardness, as well as good plasticity and toughness. This allows cold-forged aluminum to withstand greater pressure and impact during the manufacturing process and is less likely to deform or break. Die-cast aluminum is relatively soft, and has lower strength and hardness, but has better fluidity and plasticity.
  3. Different surface treatment effects: Because cold-forged aluminum has higher strength and hardness, its surface treatment effect is better and can form a smoother and more uniform surface. Due to its lower strength and hardness, die-cast aluminum has relatively poor surface treatment effects and is prone to defects such as unevenness and bubbles.
  4. Cost difference: The production process of cold-forged aluminum is relatively complex and requires more equipment and manpower investment, so its production cost is higher. The production process of die-cast aluminum is relatively simple and requires less investment in equipment and manpower, so its production cost is low.
  5. Different application ranges: Because cold-forged aluminum has higher strength and hardness, as well as better surface treatment effects, it is usually used to manufacture LED lamp casings, radiators, and other components with higher requirements. Due to its lower strength and hardness, as well as poor surface treatment effect, die-cast aluminum is usually used to manufacture some LED lamp casings, radiators, and other components that do not require high material performance.

Due to the limitations of the forging process, cold forging cannot produce products with complex shapes. In addition, cold-forged pure aluminum radiators are a preferred radiator solution that has emerged in recent years. However, due to the technical difficulty of the cold forging process, the complex forming process, and the high cost of molds, careful evaluation is required when using this solution. The die-casting process can produce products with complex shapes, with flatter surfaces, and higher dimensional consistency. However, die-casting also has disadvantages such as poor thermal conductivity of the radiator and a decrease in the thermal conductivity of the aluminum alloy.

To sum up, there are certain differences between cold-forged aluminum and die-cast aluminum in LED lamps in terms of the production process, material properties, surface treatment effects, cost, and application scope. According to the specific product requirements and application scenarios, suitable materials can be selected for manufacturing.

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