Home > News > TOP 6 things you should know about custom aluminum casting
Casting is the original and most widely used method of forming aluminum into products. Technical advances have been made, but the principle remains the same: Molten aluminum is poured into a mold to duplicate a desired pattern. The three most important methods are die casting, permanent mold casting, and sand casting.
The die casting process forces molten aluminum into a steel die (mold) under pressure. This manufacturing technique is normally used for high-volume production. Precisely formed aluminum parts requiring a minimum of machining and finishing can be produced through this casting method.
Permanent mold casting involves molds and cores of steel or other metal. Molten aluminum is usually poured into the mold, although a vacuum is sometimes applied. Permanent mold castings can be made stronger than either die or sand castings. Semi-permanent mold casting techniques are used when permanent cores would be impossible to remove from the finished part.
The most versatile method for producing aluminum products is sand casting. The process starts with a pattern that is a replica of the finished casting. Virtually any pattern can be pressed into a fine sand mixture to form the mold into which the aluminum is poured. The pattern is slightly larger than the part to be made, to allow for aluminum shrinkage during solidification and cooling. As compared to die and permanent mold casting, sand casting is a slow process but usually more economical for small quantities, intricate designs, or when a very large casting is required.
Aluminum sand cast tooling costs from $ 500 to $7,500 depending on the size and complexity of the aluminum casting part life is 5,000 parts. Aluminum dies casting tooling costs from $5,000 to $75,000 depending on the size and complexity of the aluminum die-cast part.
The most popular alloy for aluminum die casting is A380. We use A380 because it has demonstrably the best combination of physical and mechanical properties for casting, including being lightweight, very strong at high temperatures, and corrosion-resistant. A380 is one of the most commonly specified aluminum alloys with a number of significant benefits:
It offers the best combination of casting, mechanical, and thermal properties;
It exhibits excellent fluidity, pressure tightness, and resistance to hot cracking;
It is used for a wide variety of products including chassis for electronic equipment, engine brackets, gearbox cases, household furniture, power, and hand tools.
When it comes to aluminum die casting, A380 is the most popular die-cast metal choice. That's because it offers a good cost/utility ratio based on a combination of economics and predictable mechanical and physical properties. A380 aluminum's advantages and characteristics include:
The ability to cast thin walls and complex shapes
Good mechanical properties
High thermal and electrical conductivity
High strength-to-weight ratio
Environmentally friendly (100% recyclability).
Good tool life.
Very good castability.
Excellent overall value.
Aluminum is an extremely versatile metal in that it is a great candidate for a wide range of manufacturing methods, two of which are extrusion and casting. ... Whereas, casting is a process in which molten aluminum is poured into a mold and then allowed to solidify.
Strength-- As mentioned, stainless steel is stronger than aluminum. ... Workability - Compared to stainless steel, aluminum is more malleable. For castings, aluminum is much easier to work with and manipulate. Heat Resistance-- Typically, it takes less time to cast aluminum than it does with stainless steel.
The most significant advantage of aluminum die-casting compared to other processes like machining, or sheet metal forming is that aluminum can create intricate 3D designs very efficiently at a lower cost. Because of this, manufacturers are able to order customized castings that are ideal for their production needs. Aluminum die castings can turn molten metal into a near-net shape part in seconds, so machining or other operations can be eliminated. Aluminum dies castings are 100% recyclable and all of the material involved in the production of aluminum die castings is recycled. The ingot comes from recycled material and all of the excess material and any scrap castings are recycled in-house.
Aluminum die casting is used frequently in the automotive industry as a durable, lightweight alternative to steel and iron.
Its electrical and thermal conductivity properties make it well suited for the telecommunications and computer industries.
Its lightweight makes it an excellent choice for portable applications.
Aluminum A380's economic benefits and mechanical properties make it the metal of choice for a wide variety of applications and industries.
so Goal Sure Machining is divided into: