We take a client-focused approach to creating castings to ensure the final product exceeds your expectations. This involves directly coordinating with our customers, determining the best processes during design, prototyping, production, tooling and frequently testing for quality during the casting creation process. Our dual approach allows us to prototype tooling while simultaneously manufacturing castings. Learn more about our workflow process.
We take a client-focused approach to creating castings to ensure the final product exceeds your expectations. This involves directly coordinating with our customers, determining the best processes during design, prototyping, production, tooling and frequently testing for quality during the casting creation process. Our dual approach allows us to prototype tooling while simultaneously manufacturing castings. Learn more about our workflow process.
At Pentz we support our customers from first inquiry thru delivery of your production requirements. We utilize CAD development and 5-axis CNC machining to design and manufacture castings, CMM, Laser and CT Scans to verify tooling and are an ITAR-registered castings manufacturer. Learn more about the benefits of choosing Pentz.
We have experience providing castings for a variety of clients and applications and are always eager to create unique casting for low and high-volume casting production. Some frequent industries served include:
The sand casting process begins with a Pentz engineer meeting with the customer to review the proposed project and determine if it’s a good candidate. We then determine the most efficient geometry, casting process, prototyping and tooling process that should be used moving forward. Our dual approach allows us to prototype tooling while castings are manufactured simultaneously. Castings and tooling are tested for quality to ITAR-registered standards. Learn more about our project / job flow diagram.
We see the casting process as a collaborative effort—we use your spark and initial ideal and support you in every step of the production development process. Our early involvement in your project can enhance the entire engineering process. Together we can quickly identify the best design configuration, casting process, alloy, tooling approach and the best manufacturing plan to yield exceptional results. Learn more about our full casting Engineering / Design & CAD development process.
Our dual approach to prototyping and production allows us to hog out prototypes and casting tooling simultaneously. This ensures you get the prototypes and casting tooling that you need as quickly as possible. Additional services include:
Our triple path process involves the following steps:
The right casting process for your project is based on the size, complexity, alloy, physical properties required, quantities required / anticipated, schedule, and if the casting design is fixed or still developing. Pentz Cast Solution engineers will guide you through each phase of your project. Contact us today for a consultation on your project or view our casting, engineering or mold process pages below.
How do I select the right Prototype process?
Pentz Cast Solution engineers will guide you through each phase of your project. Contact us today for a consultation on your project or view our sand molding and permanent molding processes below in the meantime.
CNC machined aluminum tooling, managed sand system PLC sand system sand testing compaction results in .150 rms as cast finish detailed
The term “green sand” refers to molding sand containing about 3% temper water required to activate clay in sand to bind the sand as it is compacted to build a green sand mold. The sand mold holds its highly detailed geometry accurately just long enough to be poured in aluminum and make a casting. Casting have a superior as cast finish of 150 RMS with thin walls to heavy walls.
Green Sand Molding sand is recirculated thousands of times, so it is very efficient and ecologically sound and only requires small amounts of water. Green sand molding usually requires a total of 2% moisture additions to be made back into moldable sand.
A core is made of hard bonded sand that is shaped to create negative space(s) within a casting.
Call 425-788-6490 (x306) to speak with a Pentz Cast Solutions Sales Engineer or Representative.
Dry sand molding consists of sand mixed with chemical binders to build sand molds or cores for making sand castings. Dry sand variations include air-set self-setting chemical bonding or Sodium Silicate and CO2 gas for catalyst set. Dry Sand molds are not 100% reclaimable to be remade into molds, unlike “green sand” which is 100% reclaimable.
Casting tooling can be used to create intricate permanent molds of gray iron, ductile iron, bronze alloys and additional material from complex geometries in large proto and production castings. At Pentz Cast Solutions, we design and engineer precision ITAR-registered sand casting tooling and permanent mold tooling for low and high-volume casting production. Custom equipment Pentz engineers, designs and creates to manufacture castings and CNC machined parts per customer specifications and PO.
We make every effort to utilize existing customer-supplied tooling. Customer tooling will be inspected, evaluated, and costs-quoted so modification can be made as required to build great castings efficiently.
Pentz Cast Solutions “as Cast” 150 rms surface finish is extraordinary and unsurpassed in the industry. See Case Study: Precision Automated Sand Cast O Ring Grooves.
Only sand touches our CNC machined aluminum tooling, so every casting is built with a new green sand mold utilizing a PLC-managed sand system and extensive testing.
Production CNC machined aluminum tooling can easily build 50,000 to 100,00 castings.
Decal recesses and “O” ring grooves without machining can be considered “as cast.”
See Case Study: Precision Automated Sand Cast O Ring Grooves.
Acceptable cast in inserts include complex stainless-steel tube assemblies, large stainless-steel parts, pre-machined steel parts and even die-castings containing machined steel inserts into our aluminum castings.
See Case Study: Precor Exercise Machine.
Pentz routinely builds aluminum castings with molded in die cast parts, even with cast in steel inserts in the diecasting.
See Case Study: Cast in Diecasting.
Pentz can build castings with little 1-2 degrees to no draft depending on casting geometry and use of cores.
See: Case Studies
Our castings have extremely low porosity, assuring pressure-tight castings.
Pentz removes porosity, causing hydrogen gas and oxides in aluminum alloys by rotary degassing and flux injecting. Specific gravity tests alloy density before pouring castings[BR1] . This achieves pressure-tight, oil-tight, vacuum-tight parts, that can be anodized or polished.
We are ready to provide any quantities required from 1 to 1 million. Our precision manual green sand mold or Sinto Automated sand molding process is scalable, so if you start with one prototype in low production, we can use the same prototype to create thousands of castings with the same tooling.
For larger, higher volume castings, Pentz has Permanent mold capabilities, usually 5,000+ EAU or more. Pentz Cast Solution expert engineers will guide you through each phase of your project.
Expertise Molding
We have an extensive selection of Alloys available for casting, including heat-treated aluminum alloys. Contact us today and Pentz Cast Solution’s expert engineers will guide you through each phase of your project.
We have worked with applications ranging from aerospace to food production.
Thank you for your interest in Pentz Cast Solutions’ services. Please Contact us online or Request a Quote and let us handle all your casting needs.
Cast aluminum is a specific aluminum that is formed by casting technique. There is a wide application of cast aluminum due to its lightweight yet good strength. Cast aluminum could be seen in both daily life and industrial applications, such as cast aluminum cookware, cast aluminum chair legs, cast aluminum pumps, and more.
As a professional casting company, CFS Foundry can produce custom cast aluminum partscustom cast aluminum parts following your drawing’s specifications. There are several aluminum casting processes available at our foundry, including aluminum die casting, aluminum gravity casting and aluminum sand casting. Each casting process has its special advantages, and we can recommend a best suitable casting process according to the design of the aluminum part.
What is Cast Aluminum?Cast aluminum refers to aluminum that has been heated to its melting point before pouring it into molds for specific shapes or forms. The casting process involves heating aluminum until its melting point has been reached, then pouring it in an appropriate mold where it cools and solidifies to produce desired forms or shapes. After casting, post operations such as trimming and surface grinding are performed to achieve net shape castings.
Benefits of Cast AluminumCast aluminum, particularly from manufacturers like CFS Foundry, offers a range of benefits for various applications. Here’s a closer look at the advantages of cast aluminum:
Complex Design CapabilityCast aluminum has its ability to creat parts into complex shapes, no matter how intricate the design is. For its excellent fluidity of aluminum alloys, thet can fill mold cavities completely, and an exact solid cast piece is formed after solidification. CFS Foundry can produce cast aluminum parts with accurate dimensions and close tolerances, which might be difficult to achieve by machining or forging process.
Lightweight Yet StrongAluminum is known for its high strength-to-weight ratio. Parts made from cast aluminum can provide the required strength for great working performace, while maintaning light weig
ht part. This is not available when parts made from other casting materials such as cast steel or cast iron. This benefit makes cast aluminum a good application especially for automotive and aerospace industries.
Excellent Corrosion ResistanceWhen exposed to atmospheric conditions, aluminum can naturally form an oxide layer, this protects it against corrosion. So, after casting, cast aluminum parts have excellent corrosion resistance, which make them an ideal choice in harsh or corrosive environments, like marine applications or outdoor furniture. If there is a higher requirement, cast aluminum parts could be further anodized or powder painted to improve its enchace its corrosion resistance capacity.
Faster Speed of ProductionThe casting process of aluminum parts is always faster than other manufacturing process, such as machining or welding fabrication process. As most of the aluminum casting processes are automated, once the molds are prepared, the production process of cast aluminum parts is very fast. Cast aluminum can provide shorter lead times while high quality products.
Cost-effectiveness for ManufacturingEven with an intial investment in mold, due to the great production speed and less material waste, the cost per cast aluminum part is very economical. Besides, cast aluminum has the ability to creat a simple piece in complex shapes, and reduce or remove the need for post machining, which lower the production cost in further step.
The Casting Processes for AluminumAt CFS Foundry, there are several processes to cast aluminum into various shapes. Each casting process has its own capabilties and advantages. Here is an overview of the main manufacturing processes for casting aluminum parts:
1. Low / High Pressure Die CastingLow Pressure Die Casting (LPDC) is the casting process that can produce cast aluminum parts at low pressure, typically between 20 psi and 100 psi. In this process, aluminum is melted and then tranferred into a mold under low pressure until the aluminum solidifies. Cast aluminum parts made from this process can achieve good dimensional accuracy even in medium to high volumes. It is particularly suitable for making cast aluminum parts in thicker wall thickness.
High Pressure Die Casting (HPDC), as its name implies, creats cast caluminum parts at high pressure, typically between 10,000 and 15,000 psi. In this process, molten aluminum is injected into a mold under high pressure fastly. By high pressure die casting, thin-walled cast aluminum parts with complex shapes could be made. Besides, it also allows for high volume production. The strength of cast aluminum made in this process is the best among all the aluminum casting processes.
2. Gravity Die CastingGravity Die Casting, sometimes referred to as permanent mold casting, involves pouring molten aluminum into metal molds using gravity for permanent cast aluminum production. Molds made of steel or cast iron typically can support useable multiple cycles, which make gravity die casting an economical medium-to-high volume production method. Cast aluminum parts made from this process can achieve improved mechanical properties and finer surface finishes than sand casting method.
3. Sand CastingAs one of the most versatile casting processes available today, sand casting is not limited to make cast steel and cast iron parts, it can creat cast aluminum parts as well. Cast aluminum parts with intricate geometries are usually made in sand casting process, which is challenging by other casting methods. Aluminum sand casting process involves creating a mold from sand mixture, then pouring molten aluminum into it for solification. Next, the mold is broken away to take out the finished cast aluminum part. This process prpvides flexibility on mold design, so it supports both small and large cast aluminum parts with intricate shapes. While the surface is rougher when compared with die casting process.
Common Cast Aluminum AlloysBecause of the excellent mechanical properties and casting ability, cast aluminum is widely used by many industries. At Foundry, we have the capability to produce cast aluminum parts in different alloys, including A356, A360, A380, A383. They have unique chemical compositions, each alloy shows district advantages for different applications.
A356 Aluminum AlloyA356 aluminum alloy is the most common material in aluminum gravity casting. The T6 heat treatment can further improve its strength and will be helpful for machining operation. The main chemical elements of A356 alloy include aluminum, magnesium (0.02-0.45%), silicon (6.5-7.5%) and other elements. Due to its good castability, welding ability and corrosion resistance, it is widely used in aluminum gravity casting process to creat parts with high strength and ductility. A356 castings are widely used in automotive and aerospace applications, as well as other industries.
A360 Aluminum AlloyThe A360 aluminum alloy mainlt consists of elements like aluminum, magnesium (0.4-0.6%), silicon (9-10%) and copper (6%). These compositions increases its strength and corrosion resistance when compared to other metals. A360 can offer good pressure tightness, which is critical for fluid-handling components. The excellent castability of A360 and its aesthetic surface finish makes it a good choice for casting housings, connectors and complex automotive components.
A380 Aluminum AlloyA380 is a widely used cast aluminum alloy that contains aluminum, silicon (7.5-9.5%), copper (3-4%) and other elements such as iron, nickel and zinc. It is a versatile die casting material due to its high thermal conductivity and fluidity. CFS Foundry can cast A380 aluminum parts where strength and durability are needed, such as automotive components, electronic devices, lighting components and engine brackets.
A383 Aluminum Alloy (ADC12)A383, also known as ADC12, is also a common die cast aluminum alloy. Its composition differences can improve its casting characteristics when compared with A380 alloy. This alloy includes elements like copper, silicon, and aluminum (9.5-11.5%). CFS Foundry usually uses A383 aluminum alloy for casting production because its good balance between castingability, mechanical properties and thermal conductivity. A383 is well suited for die casting production with thin walls, high precision. Examples of A383 cast aluminum parts are gearboxes and pumps.
How To Select a Right Casting Process for Aluminum?When selecting a right casting process for aluminum parts, it is necessary to evaluate both the usage of the part and the material properties of cast aluminum alloy. CFS Foundry suggests to consider the manufaturing process from several factors in below, and we can also recommend the best process for you based on your design.
Design ComplexityThe complexity and detail of any design play an essential part in selecting an optimal casting process. High-pressure die casting specialises in producing parts with intricate geometries and tight tolerances, making it ideal for creating aluminum parts with fine details and high accuracy. So, when the cast aluminum parts have a high requirement on dimensional accuracy and surface finish, high pressure die casting is the best choice for high volume production. For simpler or thicker designed parts, gravity die casting or sand casting may offer more cost effective solutions. Besides, sand casting is also suitable for large cast aluminum parts in small volume production.
Production VolumeProduction volumes is also a necessary consideration factor for cast aluminum parts production. For high-pressure die casting, it is only cost effective for high volume production runs due to its high investment on the mold cost. Of course, it is worth to mention that the production efficiency is also very high. Medium volume projects might consider gravity die casting. While for low and prototype runs, sand casting may offer advantages due to reduced tooling costs, although its per-unit costs are higher.
Material Properties and PerformanceFor its superior strength-to-weight ratio and corrosion resistance of aluminum alloys, they are widely used in casting production. Casting process will further affect the properties. For example, high pressure die casting creates denser microstructures which enhance mechanical properties but increase porosity. Gravity die casting provides excellent material integrity which makes this approach ideal for moderate strength applications. While sand casting produces coarser microstructures which may result in parts with lower mechanical properties than expected – it is therefore vital that we clearly establish any performance expectations before choosing this form of casting as our final solution!
Surface FinishThe surface finish is also an important factor to consider when selecting an aluminum casting process. High pressure die casting can provide the finest surface quality of cast aluminum parts, and less or no machining is needed after casting. Low pressure die casting sand gravity die casting also offer good surface finish after fine blasting. While sand casting often provides rougher surface finish, which usually need further machining to achieve higher surface finish.
Cost ConsiderationsCost factor could not be ignored when selecting a casting process for aluminum parts. High pressure die casting has the advantages of speed, precision and surface finish, but it requires a high tooling investment, and is more ideal for large orders. Gravity die casing and low pressure die casting offer lower tooling cost, but its unit cost is relatively higher. Sand casting is a most econimical selection for low volume production, while its unit cost per part is the highest when compared with other casting processes, and additional machining operation is usually required for closer tolerances or higher surface finish.
Cast Aluminum vs. Forged AluminumThe fundamental difference between Cast and forged aluminum is easy to understand: Cast aluminum is the aluminum that was melted in a furnace and poured into a mold. Forged aluminum is when the metal is worked in the solid form with the help of specific tools. These two manufacturing processes will yield two materials with very different properties.
Aluminum has a wide range of uses across every major industry, however, it is often difficult to decide which grade is best suited to a specific application. The challenge becomes greater when comparing not only between alloys but also between cast and forged aluminum. Both are fundamentally aluminum alloys which often have the same alloying elements but in different compositions and quantities. However, the applications and material properties vary widely between the two.
Examples of Cast Aluminum ProductsYou may be surprised to find out that many of the commercial products you come in contact with every day may be using cast aluminum parts and components or even be made entirely from cast aluminum.
Car PartsDue to the amazing strength and light weight of cast aluminum parts, it is very popular in the production of car parts. For example, safety-critical parts like airbag housings or seat-belt retractor spools are made with diecast aluminum. In addition, steering knuckles, which support the wheel bearing, are made with this material. This is an essential part of a vehicle’s suspension, so the lightweight material helps to reduce the overall weight of the car without compromising strength or performance.
Lighting PartsDue to the light weight and good corrosion resistance of cast aluminum, it is always used as the casting alloy for various lighting parts. Cast aluminum lighting parts could be designed and produced by either gravity die casting or high pressure die casting process.
Medical DevicesMany medical devices are also made from cast aluminum, not only due to the strength but also due to its heat resistance. Some of the more common medical equipment you may see made from this metal is parts for various pumps, surgical tools, components for monitors, and even gearboxes for hospital beds.
FirearmsAnother popular application for die casting is the production of firearms. While many popular firearms may have plastic components, there are still a number of parts that are created from die-cast metals. Some of these parts may include triggers, trigger guards, trigger safetys, and much more.
Cast Aluminum CookwareFor decades, cast aluminum cookware (flater beater, dough hook, etc) has been a vital tool in a well-stocked home kitchen. The versatile product is perfectly suited for cooking on the stovetop and baking in the over. It is dishwasher safe, making for a quick and easy clean up. Despite some ridiculous reports, it is safe to use for cooking and poses no health risks at all.
If you’re looking for pots and pans made from this material, the good news is they’re everywhere. You can find brand-new sets on the websites of major retailers. If a more classic style is what you are after, you can even find vintage cast cookware on eBay.
Cast Aluminum Patio FurnitureWhen you think about investing in patio furniture you want something attractive, durable, and low-maintenance. If you also want an outdoor ensemble that’s available in a variety of styles, finishes, and colors, cast aluminum patio furniture including cast aluminum chair legs may provide you with an ideal setting to enjoy entertaining and relaxing with family and friends.
Work With CFS Foundry for Your Cast Aluminum ProjectWhether you’re sourcing aluminum die casting or aluminum gravity casting process for your project, CFS Foundry can help you with your next cast aluminum project. We’ve provided high-quality aluminum casting and machining services to a wide variety of industries for more than 30 years. Contact us today to request a quote for your cast aluminum project.
At Pentz we support our customers from first inquiry thru delivery of your production requirements. We utilize CAD development and 5-axis CNC machining to design and manufacture castings, CMM, Laser and CT Scans to verify tooling and are an ITAR-registered castings manufacturer. Learn more about the benefits of choosing Pentz.
We have experience providing castings for a variety of clients and applications and are always eager to create unique casting for low and high-volume casting production. Some frequent industries served include:
The sand casting process begins with a Pentz engineer meeting with the customer to review the proposed project and determine if it’s a good candidate. We then determine the most efficient geometry, casting process, prototyping and tooling process that should be used moving forward. Our dual approach allows us to prototype tooling while castings are manufactured simultaneously. Castings and tooling are tested for quality to ITAR-registered standards. Learn more about our project / job flow diagram.
We see the casting process as a collaborative effort—we use your spark and initial ideal and support you in every step of the production development process. Our early involvement in your project can enhance the entire engineering process. Together we can quickly identify the best design configuration, casting process, alloy, tooling approach and the best manufacturing plan to yield exceptional results. Learn more about our full casting Engineering / Design & CAD development process.
Our dual approach to prototyping and production allows us to hog out prototypes and casting tooling simultaneously. This ensures you get the prototypes and casting tooling that you need as quickly as possible. Additional services include:
Our triple path process involves the following steps:
The right casting process for your project is based on the size, complexity, alloy, physical properties required, quantities required / anticipated, schedule, and if the casting design is fixed or still developing. Pentz Cast Solution engineers will guide you through each phase of your project. Contact us today for a consultation on your project or view our casting, engineering or mold process pages below.
How do I select the right Prototype process?
Pentz Cast Solution engineers will guide you through each phase of your project. Contact us today for a consultation on your project or view our sand molding and permanent molding processes below in the meantime.
CNC machined aluminum tooling, managed sand system PLC sand system sand testing compaction results in .150 rms as cast finish detailed
The term “green sand” refers to molding sand containing about 3% temper water required to activate clay in sand to bind the sand as it is compacted to build a green sand mold. The sand mold holds its highly detailed geometry accurately just long enough to be poured in aluminum and make a casting. Casting have a superior as cast finish of 150 RMS with thin walls to heavy walls.
Green Sand Molding sand is recirculated thousands of times, so it is very efficient and ecologically sound and only requires small amounts of water. Green sand molding usually requires a total of 2% moisture additions to be made back into moldable sand.
A core is made of hard bonded sand that is shaped to create negative space(s) within a casting.
Call 425-788-6490 (x306) to speak with a Pentz Cast Solutions Sales Engineer or Representative.
Dry sand molding consists of sand mixed with chemical binders to build sand molds or cores for making sand castings. Dry sand variations include air-set self-setting chemical bonding or Sodium Silicate and CO2 gas for catalyst set. Dry Sand molds are not 100% reclaimable to be remade into molds, unlike “green sand” which is 100% reclaimable.
Casting tooling can be used to create intricate permanent molds of gray iron, ductile iron, bronze alloys and additional material from complex geometries in large proto and production castings. At Pentz Cast Solutions, we design and engineer precision ITAR-registered sand casting tooling and permanent mold tooling for low and high-volume casting production. Custom equipment Pentz engineers, designs and creates to manufacture castings and CNC machined parts per customer specifications and PO.
We make every effort to utilize existing customer-supplied tooling. Customer tooling will be inspected, evaluated, and costs-quoted so modification can be made as required to build great castings efficiently.
Pentz Cast Solutions “as Cast” 150 rms surface finish is extraordinary and unsurpassed in the industry. See Case Study: Precision Automated Sand Cast O Ring Grooves.
Only sand touches our CNC machined aluminum tooling, so every casting is built with a new green sand mold utilizing a PLC-managed sand system and extensive testing.
Production CNC machined aluminum tooling can easily build 50,000 to 100,00 castings.
Decal recesses and “O” ring grooves without machining can be considered “as cast.”
See Case Study: Precision Automated Sand Cast O Ring Grooves.
Acceptable cast in inserts include complex stainless-steel tube assemblies, large stainless-steel parts, pre-machined steel parts and even die-castings containing machined steel inserts into our aluminum castings.
See Case Study: Precor Exercise Machine.
Pentz routinely builds aluminum castings with molded in die cast parts, even with cast in steel inserts in the diecasting.
See Case Study: Cast in Diecasting.
Pentz can build castings with little 1-2 degrees to no draft depending on casting geometry and use of cores.
See: Case Studies
Our castings have extremely low porosity, assuring pressure-tight castings.
Pentz removes porosity, causing hydrogen gas and oxides in aluminum alloys by rotary degassing and flux injecting. Specific gravity tests alloy density before pouring castings[BR1] . This achieves pressure-tight, oil-tight, vacuum-tight parts, that can be anodized or polished.
We are ready to provide any quantities required from 1 to 1 million. Our precision manual green sand mold or Sinto Automated sand molding process is scalable, so if you start with one prototype in low production, we can use the same prototype to create thousands of castings with the same tooling.
For larger, higher volume castings, Pentz has Permanent mold capabilities, usually 5,000+ EAU or more. Pentz Cast Solution expert engineers will guide you through each phase of your project.
Expertise Molding
We have an extensive selection of Alloys available for casting, including heat-treated aluminum alloys. Contact us today and Pentz Cast Solution’s expert engineers will guide you through each phase of your project.
We have worked with applications ranging from aerospace to food production.
Thank you for your interest in Pentz Cast Solutions’ services. Please Contact us online or Request a Quote and let us handle all your casting needs.
Cast aluminum is a specific aluminum that is formed by casting technique. There is a wide application of cast aluminum due to its lightweight yet good strength. Cast aluminum could be seen in both daily life and industrial applications, such as cast aluminum cookware, cast aluminum chair legs, cast aluminum pumps, and more.
As a professional casting company, CFS Foundry can produce custom cast aluminum parts following your drawing’s specifications. There are several aluminum casting processes available at our foundry, including aluminum die casting, aluminum gravity casting and aluminum sand casting. Each casting process has its special advantages, and we can recommend a best suitable casting process according to the design of the aluminum part.
What is Cast Aluminum?Cast aluminum refers to aluminum that has been heated to its melting point before pouring it into molds for specific shapes or forms. The casting process involves heating aluminum until its melting point has been reached, then pouring it in an appropriate mold where it cools and solidifies to produce desired forms or shapes. After casting, post operations such as trimming and surface grinding are performed to achieve net shape castings.
Benefits of Cast AluminumCast aluminum, particularly from manufacturers like CFS Foundry, offers a range of benefits for various applications. Here’s a closer look at the advantages of cast aluminum:
Complex Design CapabilityCast aluminum has its ability to creat parts into complex shapes, no matter how intricate the design is. For its excellent fluidity of aluminum alloys, thet can fill mold cavities completely, and an exact solid cast piece is formed after solidification. CFS Foundry can produce cast aluminum parts with accurate dimensions and close tolerances, which might be difficult to achieve by machining or forging process.
Lightweight Yet StrongAluminum is known for its high strength-to-weight ratio. Parts made from cast aluminum can provide the required strength for great working performace, while maintaning light weig
ht part. This is not available when parts made from other casting materials such as cast steel or cast iron. This benefit makes cast aluminum a good application especially for automotive and aerospace industries.
Excellent Corrosion ResistanceWhen exposed to atmospheric conditions, aluminum can naturally form an oxide layer, this protects it against corrosion. So, after casting, cast aluminum parts have excellent corrosion resistance, which make them an ideal choice in harsh or corrosive environments, like marine applications or outdoor furniture. If there is a higher requirement, cast aluminum parts could be further anodized or powder painted to improve its enchace its corrosion resistance capacity.
Faster Speed of ProductionThe casting process of aluminum parts is always faster than other manufacturing process, such as machining or welding fabrication process. As most of the aluminum casting processes are automated, once the molds are prepared, the production process of cast aluminum parts is very fast. Cast aluminum can provide shorter lead times while high quality products.
Cost-effectiveness for ManufacturingEven with an intial investment in mold, due to the great production speed and less material waste, the cost per cast aluminum part is very economical. Besides, cast aluminum has the ability to creat a simple piece in complex shapes, and reduce or remove the need for post machining, which lower the production cost in further step.
The Casting Processes for AluminumAt CFS Foundry, there are several processes to cast aluminum into various shapes. Each casting process has its own capabilties and advantages. Here is an overview of the main manufacturing processes for casting aluminum parts:
1. Low / High Pressure Die CastingLow Pressure Die Casting (LPDC) is the casting process that can produce cast aluminum parts at low pressure, typically between 20 psi and 100 psi. In this process, aluminum is melted and then tranferred into a mold under low pressure until the aluminum solidifies. Cast aluminum parts made from this process can achieve good dimensional accuracy even in medium to high volumes. It is particularly suitable for making cast aluminum parts in thicker wall thickness.
High Pressure Die Casting (HPDC), as its name implies, creats cast caluminum parts at high pressure, typically between 10,000 and 15,000 psi. In this process, molten aluminum is injected into a mold under high pressure fastly. By high pressure die casting, thin-walled cast aluminum parts with complex shapes could be made. Besides, it also allows for high volume production. The strength of cast aluminum made in this process is the best among all the aluminum casting processes.
Contact us to discuss your requirements of casting spiral staircase. Our experienced sales team can help you identify the options that best suit your needs.
2. Gravity Die CastingGravity Die Casting, sometimes referred to as permanent mold casting, involves pouring molten aluminum into metal molds using gravity for permanent cast aluminum production. Molds made of steel or cast iron typically can support useable multiple cycles, which make gravity die casting an economical medium-to-high volume production method. Cast aluminum parts made from this process can achieve improved mechanical properties and finer surface finishes than sand casting method.
3. Sand CastingAs one of the most versatile casting processes available today, sand casting is not limited to make cast steel and cast iron parts, it can creat cast aluminum parts as well. Cast aluminum parts with intricate geometries are usually made in sand casting process, which is challenging by other casting methods. Aluminum sand casting process involves creating a mold from sand mixture, then pouring molten aluminum into it for solification. Next, the mold is broken away to take out the finished cast aluminum part. This process prpvides flexibility on mold design, so it supports both small and large cast aluminum parts with intricate shapes. While the surface is rougher when compared with die casting process.
Common Cast Aluminum AlloysBecause of the excellent mechanical properties and casting ability, cast aluminum is widely used by many industries. At Foundry, we have the capability to produce cast aluminum parts in different alloys, including A356, A360, A380, A383. They have unique chemical compositions, each alloy shows district advantages for different applications.
A356 Aluminum AlloyA356 aluminum alloy is the most common material in aluminum gravity casting. The T6 heat treatment can further improve its strength and will be helpful for machining operation. The main chemical elements of A356 alloy include aluminum, magnesium (0.02-0.45%), silicon (6.5-7.5%) and other elements. Due to its good castability, welding ability and corrosion resistance, it is widely used in aluminum gravity casting process to creat parts with high strength and ductility. A356 castings are widely used in automotive and aerospace applications, as well as other industries.
A360 Aluminum AlloyThe A360 aluminum alloy mainlt consists of elements like aluminum, magnesium (0.4-0.6%), silicon (9-10%) and copper (6%). These compositions increases its strength and corrosion resistance when compared to other metals. A360 can offer good pressure tightness, which is critical for fluid-handling components. The excellent castability of A360 and its aesthetic surface finish makes it a good choice for casting housings, connectors and complex automotive components.
A380 Aluminum AlloyA380 is a widely used cast aluminum alloy that contains aluminum, silicon (7.5-9.5%), copper (3-4%) and other elements such as iron, nickel and zinc. It is a versatile die casting material due to its high thermal conductivity and fluidity. CFS Foundry can cast A380 aluminum parts where strength and durability are needed, such as automotive components, electronic devices, lighting components and engine brackets.
A383 Aluminum Alloy (ADC12)A383, also known as ADC12, is also a common die cast aluminum alloy. Its composition differences can improve its casting characteristics when compared with A380 alloy. This alloy includes elements like copper, silicon, and aluminum (9.5-11.5%). CFS Foundry usually uses A383 aluminum alloy for casting production because its good balance between castingability, mechanical properties and thermal conductivity. A383 is well suited for die casting production with thin walls, high precision. Examples of A383 cast aluminum parts are gearboxes and pumps.
How To Select a Right Casting Process for Aluminum?When selecting a right casting process for aluminum parts, it is necessary to evaluate both the usage of the part and the material properties of cast aluminum alloy. CFS Foundry suggests to consider the manufaturing process from several factors in below, and we can also recommend the best process for you based on your design.
Design ComplexityThe complexity and detail of any design play an essential part in selecting an optimal casting process. High-pressure die casting specialises in producing parts with intricate geometries and tight tolerances, making it ideal for creating aluminum parts with fine details and high accuracy. So, when the cast aluminum parts have a high requirement on dimensional accuracy and surface finish, high pressure die casting is the best choice for high volume production. For simpler or thicker designed parts, gravity die casting or sand casting may offer more cost effective solutions. Besides, sand casting is also suitable for large cast aluminum parts in small volume production.
Production VolumeProduction volumes is also a necessary consideration factor for cast aluminum parts production. For high-pressure die casting, it is only cost effective for high volume production runs due to its high investment on the mold cost. Of course, it is worth to mention that the production efficiency is also very high. Medium volume projects might consider gravity die casting. While for low and prototype runs, sand casting may offer advantages due to reduced tooling costs, although its per-unit costs are higher.
Material Properties and PerformanceFor its superior strength-to-weight ratio and corrosion resistance of aluminum alloys, they are widely used in casting production. Casting process will further affect the properties. For example, high pressure die casting creates denser microstructures which enhance mechanical properties but increase porosity. Gravity die casting provides excellent material integrity which makes this approach ideal for moderate strength applications. While sand casting produces coarser microstructures which may result in parts with lower mechanical properties than expected – it is therefore vital that we clearly establish any performance expectations before choosing this form of casting as our final solution!
Surface FinishThe surface finish is also an important factor to consider when selecting an aluminum casting process. High pressure die casting can provide the finest surface quality of cast aluminum parts, and less or no machining is needed after casting. Low pressure die casting sand gravity die casting also offer good surface finish after fine blasting. While sand casting often provides rougher surface finish, which usually need further machining to achieve higher surface finish.
Cost ConsiderationsCost factor could not be ignored when selecting a casting process for aluminum parts. High pressure die casting has the advantages of speed, precision and surface finish, but it requires a high tooling investment, and is more ideal for large orders. Gravity die casing and low pressure die casting offer lower tooling cost, but its unit cost is relatively higher. Sand casting is a most econimical selection for low volume production, while its unit cost per part is the highest when compared with other casting processes, and additional machining operation is usually required for closer tolerances or higher surface finish.
Cast Aluminum vs. Forged AluminumThe fundamental difference between Cast and forged aluminum is easy to understand: Cast aluminum is the aluminum that was melted in a furnace and poured into a mold. Forged aluminum is when the metal is worked in the solid form with the help of specific tools. These two manufacturing processes will yield two materials with very different properties.
Aluminum has a wide range of uses across every major industry, however, it is often difficult to decide which grade is best suited to a specific application. The challenge becomes greater when comparing not only between alloys but also between cast and forged aluminum. Both are fundamentally aluminum alloys which often have the same alloying elements but in different compositions and quantities. However, the applications and material properties vary widely between the two.
Examples of Cast Aluminum ProductsYou may be surprised to find out that many of the commercial products you come in contact with every day may be using cast aluminum parts and components or even be made entirely from cast aluminum.
Car PartsDue to the amazing strength and light weight of cast aluminum parts, it is very popular in the production of car parts. For example, safety-critical parts like airbag housings or seat-belt retractor spools are made with diecast aluminum. In addition, steering knuckles, which support the wheel bearing, are made with this material. This is an essential part of a vehicle’s suspension, so the lightweight material helps to reduce the overall weight of the car without compromising strength or performance.
Lighting PartsDue to the light weight and good corrosion resistance of cast aluminum, it is always used as the casting alloy for various lighting parts. Cast aluminum lighting parts could be designed and produced by either gravity die casting or high pressure die casting process.
Medical DevicesMany medical devices are also made from cast aluminum, not only due to the strength but also due to its heat resistance. Some of the more common medical equipment you may see made from this metal is parts for various pumps, surgical tools, components for monitors, and even gearboxes for hospital beds.
FirearmsAnother popular application for die casting is the production of firearms. While many popular firearms may have plastic components, there are still a number of parts that are created from die-cast metals. Some of these parts may include triggers, trigger guards, trigger safetys, and much more.
Cast Aluminum CookwareFor decades, cast aluminum cookware (flater beater, dough hook, etc) has been a vital tool in a well-stocked home kitchen. The versatile product is perfectly suited for cooking on the stovetop and baking in the over. It is dishwasher safe, making for a quick and easy clean up. Despite some ridiculous reports, it is safe to use for cooking and poses no health risks at all.
If you’re looking for pots and pans made from this material, the good news is they’re everywhere. You can find brand-new sets on the websites of major retailers. If a more classic style is what you are after, you can even find vintage cast cookware on eBay.
Cast Aluminum Patio FurnitureWhen you think about investing in patio furniture you want something attractive, durable, and low-maintenance. If you also want an outdoor ensemble that’s available in a variety of styles, finishes, and colors, cast aluminum patio furniture including cast aluminum chair legs may provide you with an ideal setting to enjoy entertaining and relaxing with family and friends.
Work With CFS Foundry for Your Cast Aluminum ProjectWhether you’re sourcing aluminum die casting or aluminum gravity casting process for your project, CFS Foundry can help you with your next cast aluminum project. We’ve provided high-quality aluminum casting and machining services to a wide variety of industries for more than 30 years. Contact us today to request a quote for your cast aluminum project.
If you are looking for more details, kindly visit wrought iron greenhouse.