There are many different methods for forming aluminum, and aluminum casting is one of the most popular options that manufacturers consider.
Aluminum die casting is the method of choice and application for many automotive, industrial and telecommunications products.
Read this article to know more about aluminum die casting process
What is aluminum casting?
Aluminum casting is a metal forming process that allows the creation of complex aluminum features. Aluminum alloy ingots are heated at very high temperatures until they are completely melted. Liquid aluminum is injected under high pressure into the cavity of a steel mold, also known as an aluminum die. The mold is made up of two halves, and after the molten aluminum has solidified, they are separated to reveal the cast aluminum.
Aluminum products form with a smooth surface and are often followed by minimal or no machining. Since a steel die is used, the process can be repeated many times using the same die over and over again, making aluminum die casting faster and more mass production possible. great
Advantages of Aluminum Casting
Cast aluminum offers several advantages over other metal forming processes, which could make aluminum a popular material with applications.
One of the most remarkable is the ability to create very complex shapes that neither the extruder nor the machine can efficiently create. A perfect example of this is the production of complex automotive parts, like gearboxes and engine blocks. Other processes cannot consistently achieve the complexity and tight tolerances required for these products.
Some considerations when designing the molded part.
First, the mold must be designed to separate and allow the solidified aluminum to separate. The line marking where the two mold halves separate is called the dividing line and you must consider it in the early stages of mold design.
Comparison of green sand and die casting processes
Green sand and permanent molding are two popular alternative casting processes for aluminum die casting. The green sand process uses wet sand to mold the casting so it is less expensive than the other process. An operator will pour molten metal into a sand casting mold.
Unlike die casting, die casting requires molten aluminum to be poured into the mold. Molded objects can also be sturdier.
However, die casting offers better tolerances and better surface finishes than the other method, often eliminating the need for further surface treatment.
The aluminum casting process will depend on your budget, the purpose of the aluminum part, and the number of parts to be produced. Die casting can be an expensive method, but it is most essential if your design is highly complex and you require large volumes of parts.