Aluminum casting products are products manufactured with aluminum through a casting process. Many industries use these parts for multiple applications.
There are many processes for aluminum casting. Every method has its requirements and suitability for an application. Knowing all details about these methods is imperative to make a better selection.
This guide below will feature every detail you might look forward to for the aluminum casting products. It includes the process, its applications, and its advantages, so let’s read below.
What is Aluminum Casting?
A cast aluminum product is a component or part made using aluminum using a casting process. The aluminum casting process is a method in which molten aluminum is poured into a mold in molten form to achieve the desired shape and design.
Once the aluminum components are set into the mold and solidified, the component takes the shape of the cavity in which it was poured.
The components manufactured using aluminum casting are robust and durable. The aluminum casting products have a layer of aluminum oxide on the outer surface that protects them from corrosion.
Methods of Aluminum Die Casting
There are three types of aluminum casting processes to manufacture aluminum casting products.
Die Casting
The die-casting process is one of the most common ones. Two die-casting techniques exist: high pressure die cast and low pressure die cast. The most suitable method for aluminum components is high pressure die cast.
This process requires preheating aluminum material injected into a die mold. It is poured with high pressure to have the desired shape. As the aluminum part has solidified, it can be removed from the die. After it has cooled down, the next batch cycle starts manufacturing more products.
Aluminum casting products manufactured under this method have excellent thermal and electrical conductivity. The die-casting process is used to mass-produce aluminum components. It is popular in the medical and aviation sectors.
Sand Casting
Aluminum casting products are also manufactured using the sand casting process. This process comprises a mold made with sand.
These sand molds are then used for shaping the molten aluminum after it is poured into them. The aluminum component is removed as the aluminum is cooled down.Sand-based molds can withstand high temperatures. Hence the heated aluminum stays in it.
However, the components manufactured using sand casting still need to be finished. They have a rough surface, and the post-finishing processes are quite comprehensive. It is suitable for making aluminum-based fittings, oil tanks, aluminum gears, etc.
Permanent Mold Casting
This casting process for making aluminum parts is like the die-casting process. The die-casting process is done by injecting molten aluminum with high pressure in molds. At the same time, permanent mold casting uses gravity to pour the molten aluminum.
This process manufactures aluminum products with an excellent surface finish and exact accuracy. Hence, aluminum products used in aircraft and automobile industries that require detailed finishing and precise dimensions are manufactured using this method.
What to Look for When Selecting the Aluminum Casting Process?
When choosing the aluminum casting process, certain factors need to be considered. Such factors comprise the following:
- The design of the aluminum casting part matters a lot in choosing the relevant aluminum casting process. The larger parts are suitable for manufacturing through a sand-casting process. Permanent mold casting is ideal for intricate details and offers better dimensional accuracy.
- In cases where mass production of aluminum casting products is needed, die casting is a suitable choice because it is quick. However, after that comes sand casting; the slowest production method is permanent mold casting.
- The components that are to be prototyped must be relatively inexpensive. Hence, choosing sand casting for prototyping is a relevant approach since it is not expensive, while other methods require a high investment cost.
- The surface finishing and strength-oriented durability is offered by permanent mold casting. However, sand casting offers strength but lacks surface finishing; on the other hand, die casting offers a finished surface.
You can choose the desired process depending on your requirements in consideration of accuracy, the complexity of the design, investment, and surface finishing.
Advantages of Aluminum Casting Products
As compared to other materials, the aluminum casting components are quite advantageous; some of the benefits they offer comprise the following:
Excellent Surface Finish
Aluminum casting components offer a very smooth appearance, so further finishing processes are only needed if they are manufactured through sand casting. Due to their excellent finishing, they can be used in many industries and even in household cookware.
Suitable for Complex Geometries
Aluminum casting processes are quite efficient for manufacturing complex parts. Such parts have detailed and accurate dimensions; this process proves suitable for gaining the same.
Lightweight Components
Despite being strength-oriented and durable, aluminum casting products are light in weight, and hence they are suitable for many applications which require more delicate parts.
Applications of Aluminum Casting Products
Aluminum casting components are lightweight, durable, and strong, used in many industries. Some of these examples are discussed below:
- Most of the components used in the medical industry are manufactured using an aluminum casting process as they are lightweight and offer corrosion resistance, for instance, surgical trays, prosthetics, etc.
- Aluminum-based components are also used in automobiles, like steering wheels and brakes, and they even have complex shapes with the accuracy required in dimension.
- The culinary industry is even dependent on aluminum casting products, and most of the cookware is manufactured using aluminum because it is suitable for thermal conductivity.
- The aircraft industry requires such components that are light in weight and offer a lesser consumption of fuel. Hence, aluminum casting products used in an airplane are manufactured using the aluminum casting process.
Aluminum casting products are very crucial for most applications, but at the same time, choosing an experienced and specialized manufacturer is also essential to ensure the product is up to the mark.
At Sunrise Metal, we specialize in manufacturing aluminum components using aluminum casting with the latest equipment and with an experience of more than a decade. So, get in touch with us to cater to your project needs.