Metal casting has been around for thousands of years. The procedure has resulted in many incredible innovations for metal parts.
These parts have a wide range of uses as art sculptures, tools, and even weapons. Today casting is beneficial across many industries and has made countless lives more manageable through the creation of essential metal parts.
Types of Metal Casting
While there are several metal casting techniques, there are generally two main categories. One category uses reusable mold, while the other uses disposable/expendable molds.
Despite the differences, molds typically have a similar purpose. The casters melt blocks of metal alloys, and the liquid is poured onto the molds. After the metal has cooled down, it becomes solid. The casters remove the solid metal from the mold.
1. Disposable/Expendable Molds
These are molds that have a one-time use, and then they are disposed of, hence
their name. One of their unique features is that they are easy and quick to make. It is also an inexpensive option.
Disposable molds are made from a variety of materials including; ceramic shells, foams, or even sand bonded with resin. This type of mold is best for the production of small quantities.
2. Non-Expendable Mold
As their name suggests, these molds are meant for multiple uses. They are a more permanent option that works well for mass production. They have several advantages, including their strength and heat resistance.
Most permanent molds are made of steel or iron. They are known for their strength, heat resistance, and incredibly low porosities. While non-expendable options may be a little more challenging to create, getting a custom aluminum die-casting mold is always an option.
Aluminum Die Casting
Aluminum alloys are lightweight, versatile, and flexible. They also have many other unique properties, making them an excellent choice for metal casting. Aluminum has very high heat resistance. It is an incredible electric and heat conductor and has high corrosion resistance.
While some alloys are cheaper than aluminum, their numerous benefits justify their cost. Regardless, aluminum is still relatively affordable and has enormous uses, from ordinary usages, such as forming a metal window frame, to something more complex, like creating a metal part for aerospace materials.
Aluminum is durable, and it has a remarkable strength-to-weight ratio. Its unique qualities make it a popular choice for a vast range of products in an extensive range of industries, especially the automotive industry.
With options like custom aluminum die cast molds, companies don’t need to worry about creating the perfect molds on their own.
How Does An Aluminum Die-Casting Mold Work?
For an aluminum die casting to succeed, a very intricate and suitable mold must be made. These molds are unique because of their design. They have two tables with complex cavities with designs that will produce the right shape for the end product.
Essentially, a caster pours molten aluminum into the pits using high pressure. The liquid then cools down and hardens. The solid metal is removed from the mold. The halves make the separation and removal much more straightforward. If the molds were non-expendable, then they can be used to make more of the same.
Essential Parts of A Custom Casting Mold
Each company has specific guidelines and designs that ultimately affect the type of custom aluminum die casting mold that will work best. Regardless of the differences, mold manufacturers have particular steps they take to ensure that molds are suitable and practical to meet the required needs.
Drafts:
It is a taper applied on the vertical walls of the mold. Drafts make the removal of the die-cast metal easier. They also make the parts have a smooth finish.
Fillets:
They typically form a curve within the mold. They help eliminate unwanted sharp corners by adding concave or convex angles. Fillets help produce a more rounded and accurate shape on the final part. They also help avoid cracks and tears.
Parting Lines:
These act as a border between the two halves of the mold. Typically one half is stationary while the other can move, i.e., open and close. The parting line helps determine the direction of the moving half. They essentially make the removal of the castings easier.
Ribs:
These are designed to be load-bearing extensions in the mold. Their typical movement is perpendicular, and their primary purpose is to support the molded casts.
Bosses:
These are technically knobs. They play a crucial role in parts that need to be fastened together. The bosses essentially form the holes or receptacles where the screws or other types of inserts would typically go.
The Process of Making A Custom Mold
While making mold involves the same fundamental steps, some aspects differ based on the specified designs and requirements. The basic process involves;
Design:
The mold is designed in this stage. There needs to be a lot of communication between the client and the company to ensure that mold meets their needs. The crucial points include; the size, mechanism, and demand.
Machining:
This is usually the most extended phase of the custom process. After the design is complete, the manufacturer takes time to make the mold. There are a lot of procedures in this stage, which is why it takes so long.
Samples:
In this stage, the completed mold is tested to ensure that there are no flaws with the design. If there are any issues, the mold may be disassembled to correct the problems and then reassembled. This step will be repeated until the mold produces the desired result.
Shipping:
The final product is sent to the client. The duration will depend on several factors such as mode of transport and location.
There are several advantages to having a custom aluminum die-casting mold, including improved efficiency, output, and even quality. They make the workflow smooth for any company, which is why it is worth considering. Sunrise Metal is an excellent choice for creating custom molds for die casting.