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Aluminum Casting
Product ID: 3-1

Aluminum Casting

Aluminum Casting
Die casting and permanent mold casting together account for over 80% of all aluminum casting. Due to aluminum's low melting temperature, inexpensive steel and iron can be used for forming the dies & molds. The molten aluminum feeding the casting line is derived from three different sources: Ingots from a primary aluminum producer, molten aluminum directing from a smelting plant, or partially processed recycled aluminum scrap. Casting consists of pouring molten aluminum into molds. Once in the molds, the aluminum solidifies into the shape defined by the molds. Three different casting methods are used: sand casting, permanent mold casting & die casting. In the numerous casting alloys, the aluminum casting parts is light and has better ability to endure the higher temperature condition to operate. The aluminum die casting not only has a higher intensity and rigidity, but show the premium ability of corrosion resistance & thermolysis (spread heat) therefore it is the ideal products which used in the all kinds of harsh environment.
Aluminum casting manufacture method
Sand Casting: Sand casting is the most versatile method and the most economical for producing small quantities. Almost any shape mold can be produced from fine sand and binder mixture. After casting, the sand molds must either be hauled to land-fill or reconditioned. Thermal sand reclamation processes are available that remove the binder material from the sand and allow the sand to be reused. These processes are typically natural gas fired.
Investment Casting: Investment casting uses a ceramic mold which was created around a plastic or wax replica of the desired metal shape. Prior to casting, the ceramic molds is fired which increases the molds strength and burns the plastic & wax replica, removing it from the mold. Investment casting is capable of creating higher precision cast than sand casting.
Permanent Mold Casting: Permanent Mold Casting uses steel or other metal molds to shape the molten aluminum. Molten aluminum is forced into the mold under gravity or with the aid of a vacuum. Permanent mold castings are stronger than sand casting and less expensive for the larges production quantities. Permanent mold casting as the name suggest is a process wherein the liquid metal is poured into metallic moulds without application of any external pressure. The liquid metal enters the cavity by gravity. Permanent moulds casting is different from High Pressure Die Casting (HPDC) where the liquid metal is injected into the metal mould under very high pressure for production of thin walled smaller casting with better dimensional accuracy and surface finish. In the design of dies for permanent mold casting, usage of "cores" is an important issue. The undercut and the hollow shapes are produced with the help of additional moulds parts called "cores". For simple shapes without any without any under cuts the metallic cores could be used, whereas for undercut and complex hollow shape, which are difficult to retract, sand or plaster of pairs are employed. Permanent mould casting process are suitable for high volume production of non-ferrous alloy casting of aluminum, magnesium, copper, and zinc base alloy to limited extend for cast iron casting. Casting can be manufactured by operation of dies manually or by automatic devices or through die casting machines depending of the quantum of production.
Aluminum Extrusion: The term extrusion is usually applied to both the process, and the product obtained, when a hot cylindrical billet of aluminum is pushed through the shape die (forward or direct extrusion). The resulting section can be used in the long length or cut into short parts for use in structure, vehicles or components. Also extrusions are used for the starting stock for drawn rod, cold extruded and forged products. While the majority of the many hundreds of extrusion presses used throughout the world are covered by the simple description given above it should be noted that some presses accommodate rectangular shape billets for the purpose of producing extrusion with the wide section sizes. Other presses are designed to push the die into the billet. This latter modification is usually termed "indirect" extrusion. The fundamental features of the process are as follows: A heated billet cut from DC cast log (or for small diameters from larger extruded bar) is located in a heated container, usually around 450-500 degree C. At these temperatures the flow stress of the aluminum alloy is very low and applying pressure by means of a ram to one to end of the billet the metal flow through the steel die, located at the other end of the container to produce a section, the cross sectional shape of which is defined by the shape of the die.
Aluminum Forging: In a forging operation, aluminum billet are preheated prior into the forging press. Billet and die temperatures are two of the most critical process parameters associated with the forging process. A cold billet or die prevent the forged parts from flowing properly, resulting in a cracked or malformed products & excessive die wear. A hot billet or die causes surface melting during the forming process, and may cause the aluminum to stick to the die. Properly heated billet & dies form consistent quality products without excessive die wear, and without excessive die lubrication.

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