A356-cast aluminum is a type of aluminum alloy for casting that finds extensive usage in the modern automotive and aerospace industries. A 356-cast aluminum differs from other alloys because of its unique designation system. The designation is separated according to the principle of alloying elements, the percentage of aluminum, and the category of ingots or casts.
The designations include the following series;
- 1xx.x
- 2xx.x
- 3xx.x
- 4xx.x
- 5xx.x
- 6xx.x
- 7xx.x
- 8xx.x
- 9xx.x
This aluminum is primarily useful in aircraft applications, but other industries too utilize it. Today’s article dives deep into A356 cast aluminum, so stick around as we uncover more about this precious and important metal.
The A356-Cast- Composition
A356 cast aluminum is commonly used because it’s lightweight, easily weldable, and extremely corrosive resistant. Also, aluminum 6061 can be used as an alternative to A356-cast aluminum, as they both share an average composition of 94%.
A356- Cast Aluminum Features
The heat treatment processes are common methods used to enhance the durability of final products made using A356 cast aluminum alloys.
To achieve the best results, you need to consider getting the best experience A356 casting experts with modern heat treatment equipment to help you set up the proper temperatures. Below is a guideline that’ll help you learn various heat treatment processes used in A356 cast Aluminum.
The first option is The Use of the T5 Heat Treatment Process
This is the easiest option. It includes squeezing out the aluminum and allowing it to cool naturally at a specific temperature. The process increases a Webster hardness scale of 8-12.
The second option to consider is T6 Heat Treatment Process
The process involves squeezing out aluminum and immediately cooling it with water.
Typically, the T6 heat treatment process for A356 cast aluminum takes about 15 hours. T6 heat treatment is more complex, and it is known to increase hardness to a Webster hardness scale of 12-15.
First, the aluminum is extruded and allowed to cool naturally. Second, aluminum is melted and immediately cooled with water.
Casting Methods for A356 Aluminum Alloy
A 356-cast aluminum can be done in 3 methods. It is significant to remember that not all casting methods can be used in A356 cast Aluminum. Continue reading to better understand the most suitable methods for casting A356 Aluminum alloy.
Casting Process
Typically, the casting process involves designing desired parts by creating a mold or die that resembles the shape of the desired part. After achieving the desired shape, a molten metal acquired through melting A356 aluminum ingots(under high temperatures) is then incorporated into the die and removed. The end product is later used to produce similar parts.
Top 3 Methods of Casting A356 Aluminum Alloy
Permanent Mold Casting
Permanent Mold Casting (aka gravity die) is the most preferred method of casting A356 aluminum alloys in many industrial sectors. This method is suitable for
producing many parts reaching up to 10 kg. Even though it has a relatively low pouring rate, it efficiently utilizes gravity and solidifies faster. The mold castings also exhibit excellent mechanical properties, resulting in a smooth and automated finish.
Gravity Die Casting in A356 Aluminum – Top Benefits
- It is less expensive because it doesn’t require complex machinery to inject metal into the mold.
- It reduces the wastage of time and resources since the molds can be reused.
- It solidifies rapidly, producing high-quality casts that require less finishing.
- It can be manually or automatically done.
Plaster Casting
If you have very complicated designing parts, this would be the best method for A356 cast Aluminum. The mold comprises water, a strengthening compound, and a mixture of gypsum. The plaster pattern is either created of metal or rubber. However, most industries with complicated parts to design opt for rubber and later add the molten metal at the end.
Unlike metals, the rubber mold is easy and flexible to remove because it is covered with an anti-adhesive compound which makes it easy to remove. If you want to plaster cast A356 aluminum alloy, you need to decide your best parting line.
It can be a simple two-part or a more complex three-part. After deciding on your parting line, pour your plaster (should have a minimum wall thickness of 1.5mm) around the pattern, remove the pattern and bake the plaster to remove excess water. Wait for the mold to dry, then add the molted A356 cast aluminum. After the metal has hardened, separate it from the plaster part and take it for finishes such as grinding and heat treatment.
Plaster Casting A356 Aluminum – Top Benefits
- It allows for designing more complicated parts, such as two or three complex parts.
- The plaster molds are easy to create and inexpensive.
- It helps in filling any gaps around the mold.
Investment Casting
The method is very useful in designing complex parts using A356 cast aluminum. The process uses a shell, which is made of plaster, ceramic, or plastic following a wax pattern. Mostly the patterns are created using wax where a metal injection die is preferably used that resembles your finished part. Once you have successfully created your desired wax pattern, give it a rest in a ceramic slurry. Do not forget to cover it with the help of a sand stucco. Allow it to dry for somewhere between 16-48 hours timespan. After it has dried up, follow the given steps:
- Preheat it to melt
- Next, remove it from the furnace
- Once done, you can now create the casting by slowly pouring the metal into the desired shell
Investment Casting A356 Aluminum – Top Benefits
- It provides a wide variety of sizes; investment casting can produce up to 1000 pounds.
- It can produce impossible configurations that machine tools cannot reach.
Applications of A356 Cast Aluminum
A356 cast aluminum is used by most industries because of Its unique characteristics. Its strength, resistance to corrosiveness, and good weldability are utilized by most aircraft and automotive industries to make:
- High-velocity blowers as well as Impellers
- Pumps
- Automobile oil pans
- Automotive transmission cases
- High-strength machine parts
- High strength truck chassis parts
- Housing covers and plates
If you plan on using A356 cast aluminum, It is best to consider factors such as the desired shape you want to achieve, the casting process, cost, and, most importantly, experienced personnel to help you get high-quality products. Let Sunrise Metal be your top choice aluminum die-casting manufacturer. We know how to perfectly work on the A356 aluminum and give you the best results for you to use it in the above-mentioned industries.