Aluminum alloy die casting significantly influences product performance through its effects on mechanical properties, structural integrity, and surface quality. The high-pressure injection process ensures that molten aluminum fills complex mold cavities uniformly, resulting in parts with consistent wall thickness and minimal porosity when properly executed. This uniformity enhances tensile strength and hardness; for instance, alloys like ADC12 (Al-Si-Cu) typically achieve tensile strengths of 220–320 MPa after casting, making them suitable for load-bearing components in automotive and industrial applications.

However, improper casting parameters can negatively impact performance. Excessive injection speed or pressure may introduce air bubbles, leading to porosity that weakens the material and reduces fatigue resistance. Similarly, inadequate cooling rates can cause uneven solidification, resulting in internal stresses and potential warping, which compromises dimensional stability. The choice of alloy also plays a critical role: heat-treatable alloys (e.g., A380) can be aged to improve strength, while non-heat-treatable alloys (e.g., ADC12) offer better castability but lower post-casting strength adjustments.

Surface finish is another performance-related factor. Die casting produces smooth surfaces with Ra values as low as 1–3 μm, reducing the need for secondary machining and improving corrosion resistance when combined with coatings (e.g., anodizing or powder coating). Additionally, the ability to integrate multiple features (threads, ribs, bosses) in a single casting enhances structural rigidity compared to assembled parts, reducing failure risks in dynamic applications.