In the industrial sector, the aluminum die casting process is considered essential for different purposes, with special emphasis on the manufacturing of parts and the elaboration of products for the most varied segments. Through this practice, it is completely possible to produce high-strength pieces of different shapes and sizes that can weigh tons or a few grams, depending on their structural characteristics.
And if you want to know more about this topic and better understand how the entire aluminum die casting process works for the industry, be sure to check out the information that we have separated throughout this article and take note of the following tips.
What is Aluminum die casting?
As we summarized well, aluminum die casting is a common process in the industry, especially for the manufacture of parts and elements for different purposes and segments.
In practice, such metals or metal alloys are started in a liquid state, placed in a mold with a defined shape, and cooled for proper solidification.
Therefore, the aluminum die casting parts process can be considered as something simple, economical, and with extraordinary results for the manufacture of high corrosion resistance parts, without the need for welding or joints and, finally, with infinite customization possibilities.
Apart from these factors, aluminum die casting can also deliver ready-to-use products right after the process. However, in general, parts go through stages of finishing and completion in most industries.
How does the aluminum die casting process work?
Initially, all metallic inputs are taken from a natural reserve. After that, it is treated and selected. Then, ferrous metal parts are made, with carbon steel and iron, and non-ferrous metal parts, such as copper, zinc, aluminum, and magnesium. build a mold for the manufacture of future parts.
Thus, such a design die casting needs to anticipate the metal solidification shrinkage, in addition to future die casting machines processes.
In practice, the “primary mold” can be built in different materials, as well as in styrofoam, resin, wood or another type of metal. With this process finished, the mold is finally manufactured and, subsequently, filled with some type of material suitable for casting, such as sand casting, for example.
Here, at this stage, the cores can also be inserted, elements used to drill and create spaces in the final piece.
Finally, the metal melting process is carried out, in which the hot casting liquid is poured into the mold, which in turn will solidify and create the predicted geometry. After that, the new metal part is demoulded and, in general, goes on to a finishing and cleaning stage.
Do you know how it works and what the steps are in the molten aluminum die casting parts process?
Parts made of aluminum casting aluminum alloys are all around us every day, yet perhaps you have never wondered about their manufacturing process.
A lot of people don’t know, but from its raw state to the finished product, aluminum alloys need to go through different processes.
Want to know more? In this context, Castingod explains in detail how the stages of the molten aluminum die casting parts process work, it’s worth checking out!
How does the casting process work?
The casting process basically consists of heating the metal at very high temperatures until it is possible to reach the melting point.
At the melting point, the aluminum alloy changes from its solid state to the liquid state, allowing it to be poured into molds with varied formats and made based on the specifications of the parts to be produced.
Casting process steps
Now that you basically know how it works, get to know in detail all the steps of the molten aluminum die casting parts process:
Making the Model:
Making the model is the first stage of the molten aluminum die casting parts process, which consists of building a prototype with the shape of the part to be cast.
The model can be built in different materials such as wood, aluminum alloy, plastic, styrofoam, among others, and will serve as a basis for the construction of the mold for the cast aluminum alloy parts.
Making the Mold:
The mold is where the molten aluminum alloy will be placed to obtain the shape of the developed model.
In order to fulfill their function, the molds are manufactured in refractory material, such as sand casting, based on the model that, after being removed, leaves the shape of the desired part in the mold.
Die casting Machine uses different parameters to make die cast aluminum. It includes:
- investment casting
- metal casting
- sand mold
- aluminum casting and aluminum die casting
Making the Core:
The cores have the purpose of forming the holes and recesses of the part, being also produced in refractory material, they are placed in the molds before they receive the molten aluminum alloy.
Melting:
In melting, the aluminum alloy chosen for making the part is placed in an oven capable of reaching high temperatures so that it changes its structure from its solid state to a liquid state.
Pouring:
After melting, the aluminum die castings, still in a liquid state, are placed in the mold, so that it acquires the shape of the desired part, through the pouring process.
Demoulding:
After pouring, wait for the aluminum die castings to cool down and return to their solid state, then de-mold the part, that is, remove the mold and also the cores that gave the new shape to the aluminum die castings.
Cleaning and Deburring:
After demolding, it is necessary to take care of the finishing of the parts, removing burrs and using abrasive jets to remove encrustations from the mold in the cast part.
Quality Control:
Lastly, the castings manufactured by Castingod undergo rigorous quality processes that aim to ensure that the part was produced in accordance with the standards and with the initial design.
Where to find molten metal aluminum casting and custom castings?
Looking for cast molten metal aluminum casting parts, custom-made for your projects? Count on Castingod!
What are the types of aluminum die casting?
Basically, there are three types of aluminum die casting parts process in the plant, each with different characteristics and molding procedures.
And to get to know them better, we separate the following list. Check out!
Sand casting
Sand casting, as the name suggests, is characterized by molding parts from a structure made of the same material. Thus, initially, a primary model of the piece is created, which can be made of wood or metal.
In sand casting, it is always recommended to oversize the measurements, considering the volumetric contraction of the molten metal aluminum casting during its solidification.
Finally, in general, it is also advisable to perform a surface finish on the final piece, as the surface tends to become porous and impregnated by sand at the end of the manufacturing process.
Mold casting
In this case, the aluminum casting parts process takes place in the same way as the previous one, but with different inputs used for molding the part, such as steel mold, for example.
Thus, the metal is poured under high pressure into the cavities of an extremely resistant mold, obtaining dimensional accuracy and an impeccable surface finish.
The negative side of this type of die cast, especially in relation to sand molds, refers to the high cost of die casting equipment and the possibility of creating bubbles and failures in the parts, thus demanding rework.
Centrifuge
Another possible type of aluminum casting takes place using centrifuges. In this case, the steel molds are rotating at high speed around its own axis, while the metal alloy is inserted into the cavities, thus generating a very thin layer of high corrosion resistance grains on the surface of the part.
Although the finish is superior, it is also worth mentioning the high cost of this manufacturing process in relation to other models already mentioned above.
Wax
Finally, another type of metal die cast existing in the industry is wax or also referred to as lost wax casting. In practice, this model is more suitable for molten metal aluminum castings that are difficult to die casting machines or that demand better surface finishes and more exact dimensional accuracy.
Thus, the pattern is made in wax shape, which is then melted, leaving a cavity in the mold that will serve as a container for the liquid molten metal fills aluminum casting with the proper shape of the final piece.
What are the advantages of the aluminum die casting parts process?
As we have seen, there are different types of aluminum die casting parts processes, each with different methods and inputs.
But regardless of the model chosen by the industry, the advantage that such a process adds to the manufacture of parts is indisputable. For example:
- low production cost;
- results of extreme resistance and durability;
- diversification of models, sizes, and formats;
- does not depend on welds or joints, which would influence the quality of the part;
- mass production.
In summary, these are some tips and useful information about the aluminum die casting parts manufacturing process, its main characteristics, types, and practical advantages for some manufacturing of industrial parts. Did you like it? Be sure to check out other blog posts.
Castingod:
We develop the entire die cast project, which ranges from the manufacture of models to the production of parts within the specifications of the desired standards. We work with the purpose of serving our customers well, providing high-quality products, and aiming at the best standard of service.
