There are three main metal casting processes suitable for aluminum. Below are the processes and their peculiarities.
Die casting is the most popular aluminum casting process for casting aluminum parts. There are two processes: low-pressure die casting and high-pressure die casting, with the latter being the most suitable for the material.
Die casting involves preheating the aluminum and injecting it under high pressure into a die mold designed according to the intended product. On cooling, the cast aluminum part is removed from the die, and the cycle is repeated after the die cools down.
One of the advantages of die casting is that the die-casted aluminum has excellent electrical and thermal conductivity. Furthermore, they are strong and resistant to corrosion, wear, and heat.
Die-casted aluminum parts are applicable in the mass production of parts in culinary, aerospace, and medical industries.
Sand casting is the most common casting process in manufacturing. It is applicable here due to the ability of the sand to withstand elevated temperatures.
The process involves preparing a mold using sand. Afterward, the aluminum material is heated, and the molten aluminum is poured into the sand mold. On cooling, the casted aluminum part is removed.
Sand cast aluminum has low dimensional accuracy and a rough surface finish. Therefore, it most time requires post-processing options such as trimming. The aluminum casting process applies to making aluminum gears, fittings, gas and oil tanks, etc.
Permanent mold casting is similar to die casting. However, the difference between the processes is the mechanism of injecting the aluminum into the mold. Unlike die casting, permanent mold casting uses gravity instead of high or low pressure to fill the mold. As a result, it lessens turbulence during the injection process.
Aluminum casts made with this process has stronger with a good surface finish and close dimensional accuracy. The process applies to making aluminum parts in the automotive and aircraft sectors.
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