Aluminum-based components are widely used for numerous applications these days, and it is because of the exceptional properties it possesses. The products made with aluminum for the automobile industry, aviation, consumer goods, electronics, etc., are suitable because aluminum is a long-lasting and lightweight material.
Aluminum is selected because of its superior properties and ability to withstand all environmental impacts. However, the two most common terms associated with this material are cast aluminum and die-cast aluminum.
The two terms are different, and if you are looking forward to understanding this difference, you must go through the guide below.
What is Meant by Cast Aluminum?
Cast aluminium comprises all such products of aluminum that undergo different casting processes to manufacture. These are casted aluminum products, and the process involved in manufacturing them may consist of sand casting, permanent mold casting, gravity casting, ceramic mold casting, etc. can be carried out.
The selection of the casting process of aluminum casting depends upon the application’s nature and the alloy of aluminum used. In most aluminum-based products it is not always 100 percent aluminum material used. This could also be mixed with a tiny proportion of other materials.
What is Meant by Die Cast Aluminum?
On the other hand, die-cast aluminum is a casting process that creates aluminum casting under a high-pressure casting process.
In this process, the die, also known as mold, is filled with molten aluminum with high pressure and left to settle. Upon solidification, the die is removed when the product cools down, and the aluminum casting product is obtained and ready to use.
This process is very popularly used for manufacturing aluminum-based products for many industries for its capability to offer consistent production in a large volume with accuracy.
Advantages of Cast Aluminum
Cast aluminum products are backed with multiple advantages, and some of these advantages are as follows:
- The structure of the cast aluminium is robust; hence, this strength offers the ability to withstand different temperatures and conditions. Moreover, the weight of the products manufactured under the cast aluminum process is also very light; hence it suits all applications.
- It is known for its excellent heat-resistant properties, and hence when it comes to use for applications in heat-oriented aspects, cast aluminium products offer to be the best choice.
- It is suitable for manufacturing components used in home appliances, cooking ranges, and furniture that has aluminum components.
- The process of casting aluminum is very cost-effective and durable. Hence, components can be used for years without wear and tear once manufactured.
- Electronics using cast aluminum components can be manufactured to deal with all kinds of fluctuations due to the changing temperature and electrical implications.
Advantages of Die Cast Aluminum
Die-cast aluminium components come with multiple advantages, and this process also is suitable to offer numerous benefits, some of which may comprise the following:
- Die-cast aluminum manufacturing is a process that is ideally suitable for products that have highly complex shapes and designs as it goes well to create them.
- The die-casting process is suitable to have opted in the case of manufacturing large volumes of aluminum products.
- The aluminum components manufactured using the die-casting process are long-lasting; they have a lot of strength and offer stable dimensions compared to other methods.
- The components that need to be manufactured with thinner walls can be manufactured using the die-cast aluminium process, which is not possible by other methods.
- The tolerance level of the die-cast aluminium components is also very high, and hence they handle challenging situations.
Factors Affecting the Aluminum Components Manufactured using Casting Process
The two processes of manufacturing aluminum components cast aluminium or die-cast aluminium, are carried out to cast aluminum components. Hence, certain factors impact the production of the components using these methods, and this comprises of the following:
Choosing Appropriate Material
The kind of aluminum you select also depicts the price of the components, and hence it is an essential factor on which the process also depends. Whether the process is die-cast aluminium or other casting processes, the material’s quality will decide the component’s strength and aesthetic appeal.
Cost of Production
The cost of production is significant to consider; when high volume is produced, the cost of production is low, and hence die-cast aluminum is suitable to go for. However, when small-scale production is carried out, the cost of production is better in the cast aluminium processes.
Cost of Mold
Aluminum components are manufactured using molds, and molten aluminum is poured into these molds. The cost of the mold plays a vital role in identity fitting the cost of the production and component. Irrespective of the process chosen, the cost of the mold is a factor to consider when manufacturing aluminum components.
Further Finishing Process
Aluminum components are floated in the market once they are entirely ready; this also ensures the surface finish of the components. Some cast aluminum processes offer a finely finished output, whereas some don’t.
Even in the case of die-cast aluminium, the trimming and edge finishing of the aluminum component is a crucial consideration. This added finishing also has a cost that is a part of the component cost.
Some aluminum components are of such a nature that despite turning out finished in all aspects, the additional processes, such as electroplating, are essential for their usability. Hence, the cost of such additional finishing also is an important consideration.
Which Process to Choose?
Die-cast aluminum or cast aluminum are both popular ways of manufacturing aluminum components having their pros. However, it is suggested that the cost of setting up the die-casting process is higher; hence it must be opted for the vast volume production.
On the other hand, the cast aluminum process is affordable and may go well in producing small volumes.
Once the process is finalized, choosing the proper manufacturer is another important consideration. Sunrise Metal provides all kinds of techniques needed to manufacture aluminum components at an affordable price. So, if you are looking forward to having your cast aluminum components ordered, you must contact us today.