Casting is a process in which metal (liquid state) is transferred to the mold to get a specific shape. This process is important in various industries, and you may get confused between various types. In this blog, we’ll learn about cast aluminium vs die cast aluminium, and how they are different from each other.
Cast Aluminium – Overview
The process of creating cast aluminium is not too hard to understand. First, You need to heat the aluminum at very high temperatures. The molten aluminum you get is then transferred to different types of molds – the idea is to achieve a particular shape that you can use to serve the purpose at hand.
Do note that accurate formation of the mold is very important for the process, as it directly impacts the surface and end quality of the aluminum casting.
As soon as the coating process is complete, the aluminum castings immediately form an exterior layer of aluminum oxide that ideally protects the substance from the unwanted effects of corrosion.
Different Types of Casting Molds are Used for Cast Aluminium
As we have already mentioned, casting mold holds great importance in creating aluminum casts. Below we have listed different types of casting molds and their properties:
Steel Molds: It is preferred because its melting point is low when compared to aluminum, which is good for the quality of the outcome.
Sand Molds: It’s popular because of its heat resistance, affordable pricing, and flexibility.
Die-casting Molds: It’s one of the best commercial methods. The molten metal is transferred to mold under high pressure to create bulk products.
Shell Molds: In this process, manufacturers insert melting sand into ultra-thin shells using resin. This gives accurate results, but it’s a costly procedure.
Ceramic Molds: The ceramic molds have wax or plastic that melts during the firing. As a result, the mold is open or molten aluminum giving precise results.
Plaster Molds: These molds have plaster mix poured over wax. The wax melts as soon as the mold heats, giving a greater casting surface.
Permanent Molds: Permanent molds are made from very durable substances. The molten metal is transferred to these molds, which instantly solidifies.
Die Cast – Overview
Die-casting is the simple procedure of injecting molten metals like aluminum, zinc, alloys, etc. into already-made molds known as die-casting molds. Various die-casting tools, known as molds, are steel manufactured for a single project.
Important Note for Beginners: The intention of the aluminum cast and die-cast is the same: transferring molten metal to molds to get desired shapes. Only molten aluminum is used in the aluminum cast, and it can use various molds.
However, the difference lies in the fact that die casting is a type of casting that deals with various metals, including aluminum. It has many types and procedures. As a result, the multiple processes have unique advantages on the casts.
Types of Die Casting Processes
The most popular types of die-cast processes used are the hot chamber and the cold chamber. Here is detailed information on both procedures:
Hot Chamber Die Casting
Hot Chamber Die Casting is the perfect method for metal with low melting points using a hydraulic system. For example, zinc, tin, lead, and magnesium alloys. It is not used for high melting point metals because it can damage the pump.
Cold Chamber Die Casting
Cold Chamber Die Casting is the perfect solution for dealing with metals with high melting points (example aluminum.) So, the process begins by injecting the metal into a cold chamber before adding it into the molds. In this process, the pressure ranges between 2000 to 20000 PSI.
The Procedure of Die Casting
Here is the process of die casting:
Clamping: This step involves thoroughly cleaning the die to eliminate impurities. It is followed by lubrication for better injection. Finally, you will clamp and close the die with high pressure.
Injection: Now, the process of metal melting begins. Once the metal is melted, it is transferred to the shot chamber. You can follow the hot or cold chamber process according to the metal.
Cooling: You must allow the metal to cool and set into a solid shape. It will take the shape of the particular mold.
Ejection: You can now unclamp the die mold. Then an ejection mechanism is used to take the solid casting out of the die.
Trimming: The various die-casting tools are used to remove extra metal and give a perfect shape to the metal.
Advantages of Cast Aluminium
Here are some advantages of cast aluminum:
- Cast aluminum is lightweight and still has a notable structure and strength, which makes it perfect for creating components for general, automotive, and medical casting.
- It features heat resistance and strength which is great for automotive casting.
- Aluminum is on the affordable side, which makes it a good option
- It is perfect for various appliances as it has good thermal conductivity.
Advantages of Die Cast
Here are some advantages of die-casting aluminum:
- The die-casting process is ideal for large-scale production
- The process can make complex designs that are more durable and stable
- The results are stronger than other casting methods
- The process is very flexible, as it can create thousands of the same molds.
- The method is compatible with various metals and their unique properties.
Is Die-cast Aluminium the Same as Cast Aluminium?
The cast aluminum process is when you transfer molten aluminum to various molds to create specific shapes of your choice. The molds can be permanent, sand, die-cast, or shell, depending upon project requirement.
On the flip side, in the aluminum die-casting process, the molten aluminum is forced with the help of high-pressure die-casting into the molds. The high-pressure injection and hydraulic procedures make it a popular commercial process for creating bulk and precise objects.
Also, there are two processes of die-cast: the hot chamber and the cold chamber. The aluminum follows the cold chamber because it has a high melting point. Therefore, it was transferred to the cold chamber before being put into the mold.
To explore the applications of die-casting aluminum, contact Sunrise Metal now. Sunrise specializes in aluminum die casting machining and has 10+ years of expertise and experience to assist in prototyping to full-scale production for various industry needs. Visit our website today for further details.