Aluminum is one of the most abundant elements on the earth, and many things around us are manufactured using aluminum. However, manufacturing products from aluminum requires using some technological processes and methods that help shape them and ensure their usability.
If you are looking forward to knowledge about aluminum casting and the different applicable technologies, you must go through this guide below; we have featured a detailed insight into aluminum casting, so let’s read below.
What Is Aluminum Casting?
Aluminum casting is a process that is carried out by heating aluminum to reach its melting point, and then it is poured into the molds to take the shape of relevant molds.
There are different methods of aluminum casting, each having its specifications; these methods comprise the following:
● Die casting
● Sand Casting
● Permanent mold casting
Depending upon the size of the component and the finishing and speed, the decision regarding which method to choose is taken, which requires careful consideration.
Technologies for Manufacturing Aluminum Casting Products
Aluminum casting technology is one of the crucial considerations when manufacturing products based on aluminum; different aluminum casting technologies are associated with the concept of die casting. These aluminum casting technologies include the following:
Vacuum Die Casting Technology
Vacuum die casting is an aluminum casting technology that helps evacuate the gas within the cavity. This is done because it helps the aluminum melt, and the mold is filled with pressure.
This technology is used for its multiple characteristics, like the porous texture being reduced using vacuum die casting, and it offers a hard and robust component having improved mechanical properties.
The vacuum die casting uses a mold with a passage area for the exhaust. In the case of a larger exhaust area, the appearance of the technology application is obvious.
Oxygenation Die Casting
Oxygenation die casting is another aluminum casting technology in which oxygen gas is filled before die casting occurs. In other die-casting processes, gasses like hydrogen and nitrogen are used.
The mold contains oxygen already in this technology. When the aluminum is added to this mold in a molten form, some oxygen discharges from the exhaust corner, and the remaining one reacts with the metal.
As soon as the residual oxygen reacts with molten aluminum, fine particles are obtained, and a vacuum allows the mold vacuum to form. This creates a chemical reaction between aluminum and oxygen, and for production safety, the filling of oxygen should be controlled.
If it is high, the degree of oxygen dispersion has no impact on the casting; in fact, it makes it harder. Multiple housing made out of aluminum casting can be manufactured using this process which comprises a housing for heat exchanger, computer brackets, housing for hydraulic transmission, etc.
This method is suitable for aluminum castings treated with heat and subject to extremely high temperatures as they can stay intact in such temperatures.
Semi-solid Technology for Aluminum Die Casting
In a semi-solid die-casting technology, aluminum in the liquid state is left for solidification; after it has solidified about fifty percent, a slurry of the semi-solid state is obtained at a particular cooling rate. This slurry is then die-casted to make the aluminum components.
Semi-solid die casting can be carried out using two kinds of processes, and one is known as flow forming and the other one as thixoforming.
In the flow forming process, the metal in molten form is present in the barrel of injection molding, and then using a screw device, the barrel is allowed to cool down and make a semi-solid slurry which can then be poured into the molds.
The thixoforming method requires the aluminum in solid form to be fed into the molding machine, which has a screw injection. It helps in the die-casting of aluminum particles in a semi-solid form by heating it.
To achieve the right semi-solid die casting, the slurry must turn out perfect; hence, the cooling process and control of the liquid proportion matter a lot.
Extrusion Technology for Aluminum Die Casting Products
In extrusion die casting, the part is manufactured using molten metal. It has better mechanical properties, offers compactness, and is one of the most innovative technologies that can replace all die-casting technologies.
This process manufactures aluminum products by adding heated aluminum in the mold, and then a cross-section is achieved based on the desired dimension. Once the part has solidified, it could be cut down to the directed dimensions and subjected to a different machining process for adding screw holes to fit the pieces together.
Electromagnet Pump Pressure Aluminum Casting
Electromagnetic pump aluminum casting is a casting princess that uses low pressure. This low-pressure electromagnetic force acts on the molten metal and reduces the oxidation usually present in high-pressure processes.
Through a low-pressure electromagnetic process, the transportation of the liquid aluminum is carried out in the molds very smoothly with a non-touch method. Hence, due to the smooth flow, secondary pollution is eliminated.
It offers a smooth surface and excellent mechanical properties, becoming popular in manufacturing aluminum casting parts.
Why is aluminum casting opted for different applications?
Aluminum metal has many such properties that make it suitable for different applications. Hence, aluminum casting is a suitable method when it comes to choosing the process of manufacturing parts in different industries.
It offers multiple advantages when used with automobile applications, the food and beverage industry, the aviation sector, and much more; some of these advantages comprise the following:
- Offers light in weight products that could be of any size, small or big; as much as compactness is needed, aluminum casting processes offers it in the product.
- These methodologies allow the aluminum component to pass through multiple pressures and temperatures, making them strength oriented and capable of handling different temperatures.
- Casting aluminum leads to an affordable component collection that is also durable.
Aluminum casting is a commonly approached method to manufacture aluminum-based products and components. However, choosing a manufacturer that offers high quality and precision in the components is equally important.
At Sunrise Metal, you can find multiple methods and technologies of aluminum casting being implemented, and with our expertise and experience, you can make your projects successful.