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What are the methods of aluminum casting?
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Sand casting: A casting process that uses sand particles (such as clay sand) to create molds. It is suitable for producing castings with complex shapes and large dimensions, but it offers relatively lower surface accuracy and dimensional consistency.
Metal-mold casting: This process uses permanent metal molds—such as cast iron or cast steel molds—and achieves higher casting density and improved mechanical properties through rapid cooling. However, attention must be paid to venting and crack control.
Die casting: Aluminum alloy liquid is injected into a mold at high pressure and high speed, offering high production efficiency and excellent surface finish. It’s well-suited for mass-producing thin-walled, complex parts; however, the equipment cost is relatively high, and it’s prone to porosity.
Low-pressure casting: This process uses low-pressure gas to smoothly fill the mold with molten aluminum, resulting in castings with excellent density and a reduced tendency toward shrinkage porosity. It is commonly used for high-demand components such as automotive castings.
Gravity casting: This process relies on gravity to pour molten aluminum into a mold. It includes metal-mold gravity casting and sand-mold gravity casting. The process is simple and relatively low-cost, making it suitable for medium-precision castings.
Squeeze casting: Combines pressure and die casting, using the squeezing action to improve the density of castings and reduce defects. It is suitable for components with high-performance requirements.
Continuous casting—such as oil-gas slip casting—produces ingots in a continuous manner, which can improve surface quality, reduce defects (such as segregation nodules), and enhance production efficiency. This method is particularly suitable for high-end aluminum alloy materials.
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