Aluminum Casting

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Aluminum is well known for being lightweight. In fact, it is almost three times lighter than iron, with a density of 2,700 kg/m3. Remarkably, the low density of aluminum does not affect its strength. Aluminum alloys have a wide range of strength characteristics with tensile strengths ranging from 70 to 700 MPa. At low temperatures, the strength of aluminum increases, while at high temperatures, it decreases.

Aluminum can also be easily machined, and the power required is low due to the lower density. The high levels of malleability of aluminum give it the ability to be extruded easily. This enables the product to be bent and rolled, and is a key characteristic in the creation of aluminum foils.

Aluminum is widely applied in different casting parts serving a range of industries, both non industrial and industrial uses. aluminum foundries use various casting technologies, and quality is one of the key factors in deciding which technology is suitable. Aluminum casting methods vary in different manufacturing processes, from sand casting, die casting, pressure die casting, continuous casting, shell mold casting, etc. Each aluminum casting process will have its advantages and disadvantages. 

Depending on the casting’s size and complexity, we can choose the most suitable method. 

Aluminum investment casting

Aluminum investment casting produces a wide array of complex and lightweight components. By heating the material above its melting point and pouring it into the mold, it will solidify into the required 3D shape. First, a pattern is produced for mold preparation, then wax is injected into the mold. Depending on the project type, die casting may be used. If a stronger casting is required, a semi-permanent or permanent mold casting may be used. Next the mold is sanded and de-waxed. Finally, the aluminum casting is polished and tested and machined into a final product.

Aluminum castings are popular in the automotive, aerospace, and machinery industry. They are used for a number of commercial and industrial applications due to their ability to withstand high operating temperatures, thermal conductivity, and full recyclability. Depending on the intended mechanical properties and project demands, aluminum castings are selected for their lightweight and durable features.

Aluminum Die Casting

Die casting is ideal for large order quantities and large-scale pieces because it delivers consistency and repeatability.

Aluminum die casting delivers ideal tolerance control and surface finish with high volume capacity. The quenching transfer time is less than 15 seconds, delivering consistently precise die cast parts.

Low Pressure Aluminum Die Casting Process

Our die casting machines inject molten aluminum into the die. When the molten aluminum solidifies, the casting is ejected. Complex projects use hydraulic cylinders to achieve perfection and accuracy. The end result is a lightweight and durable product that is fully recyclable and reusable in production. 

For many years, Zen Young Foundry has been providing customized metal casting services for various industries and project types.

Six Industries Where We Can Provide Customized Services:

Pump & Valve Parts

Compressor Parts

Train & Railway Parts

Cylinder & Gear Box

Mining & Engineering Machinery Casting Parts

Auto & Aerospace Parts

If you are looking for a solution that fits your custom metal Sand casting project, Zen Young can help you produce perfect metal parts through a reliable casting process. We always welcome special material and difficult parts and would like to help our comstomers utmost.

The Types of Casting Processes:

Sand casting

The material used to make molds for sand casting is sand, not ceramics. Due to the roughness of sand, sand casting is most commonly used for large castings, which usually require less detail precision and tolerances.

Shell mold casting

Shell mold casting is a metal casting process similar to sand casting, in that molten metal is poured into an expendable mold. However, in shell mold casting, the mold is a thin-walled shell created from applying a sand-resin mixture around a pattern. The pattern, a metal piece in the shape of the desired part, is reused to form multiple shell molds. A reusable pattern allows for higher production rates, while the disposable molds enable complex geometries to be cast. Shell mold casting requires the use of a metal pattern, oven, sand-resin mixture, dump box, and molten metal.

Investment casting

Investment casting is one of the traditional casting methods. That is, the metal is heated to the temperature of the molten liquid, and then the material is poured into a mold designed with a suitable negative space and gated to effectively completely fill the molten metal. Once the metal has cooled and solidified, the metal part can be removed from the mold for finishing. Investment casting, also known as lost wax casting, is usually used to make jewelry and metal parts with complex shapes. 

Die casting 

Die casting is a kind of metal casting process, which is characterized by forcing molten metal under high pressure into the forming cavity. The cavity is made using two hardened tool steel molds, which have been processed into a certain shape, and die casting works similarly to injection molds.

Lost foam casting

Lost foam casting is a type of evaporative pattern casting. it maintains outstanding advantages, especially in casting complicated and precise molds.Unlike traditional methods which include the pattern withdrawn process before casting and require skillfulness in the pattern removal step, with respect to the lost foam method, the pattern is evaporated when the molten metal is poured into helping to reduce these considerations.

We will choose different casting methods for processing according to the product shape, material and your working conditions. Many years of processing experience can guarantee the quality of the casting parts.