![]() Alloy 413.0 - Outboard motor parts such as pistons, connecting rods, and housings.Alloy 360.0 - Frying skillets, cover plates, instrument cases, parts requiring corrosion resistance.Alloy A380.0 - Streetlamps housings, typewriter frames, dental equipment.Typical applications of die cast aluminum alloys include: Aluminum die castings weighing up to about 5 kg are common, but castings weighing as much as 50 kg are produced when the high tooling and casting-machine costs are justified. The die casting process consumes almost twice as much tonnage of aluminum alloys as all other casting processes combined.ĭie casting is especially suited to production of large quantities of relatively small parts. In the United States alone, about 2.5 billion dollars worth of aluminum alloy die castings is produced each year. ![]() Die CastingĪlloys of aluminum are used in die casting more extensively than alloys of any other base metal. Extensive research has been conducted to find ways of reducing such porosity however, it is difficult if not impossible to eliminate completely, and die castings often are lower in strength than low-pressure or gravity-fed permanent mold castings, which are more sound in spite of slower cooling. ![]() However, it should be kept in mind that in die casting, although cooling rates are very high, air tends to be trapped in the casting, which gives rise to appreciable amounts of porosity at the center. When applied to castings, the term quality refers to both degree of soundness (freedom from porosity, cracking, and surface imperfections) and levels of mechanical properties (strength and ductility). Quality factors are also important in the selection of a casting process. Small castings usually are made with metal molds to ensure dimensional accuracy. Because metal molds weigh from 10 to 100 times as much as the castings they are used in producing, most very large cast products are made as sand castings rather than as die or permanent mold castings. For a considerable number of castings, however, dimensions or design features automatically determine the best casting method. In terms of feasibility, many aluminum alloy castings can be produced by any of the available methods. The most important factors for all casting processes are: There are many factors that affect selection of a casting process for producing a specific aluminum alloy part. Other processes such as lost foam, squeeze casting, and hot isostatic pressing are also mentioned. ![]() These processes, in decreasing order of amount of aluminum casting, are: die casting, permanent mold casting, sand casting (green sand and dry sand), plaster casting, investment casting, and continuous casting. Aluminum is one of the few metals that can be cast by all of the processes used in casting metals. ![]()
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