Aluminium die casting processes are classified as Ingot casting or Mould casting. During the first process of aluminium die casting, primary or secondary aluminium is cast into rolling ingot (slab), extrusion ingot (billet) and wire bar ingot which are subsequently transformed in semi- and finished products.
The second process of aluminium casting is used in the foundries for producing cast products. This is the oldest and simplest (in theory but not in practice) means of manufacturing shaped components.
This page exclusively describes some methods of aluminium casting which can be divided into two main groups :
Other techniques such as "lost foam" or "wax pattern" casting processes are also used but their economical importance is considerably lower than both listed techniques.
SAND CASTING
In aluminium sand casting, re-usable, permanent patterns are used to make the sand moulds. The preparation and the bonding of this sand mould are the critical step and very often are the rate-controlling step of this process. In aluminium sand casting, two main routes are used for bonding the sand moulds:
The sand cores used for forming the inside shape of hollow parts of the aluminium casting are made using dry sand components.
Normally, such moulds are filled by pouring the melted aluminium in the filling system. Casting Mould designing is a particularly complex art and is based on the same principle as gravity die casting
In the "low pressure" sand casting technique, the melted metal is forced to enter the mould by low pressure difference. This more complicated process allows the production of cast products with thinner wall thickness.
ALUMINIUM DIE CASTING
Aluminium die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.
Aluminium die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Aluminium die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.
History of Aluminium Die Casting:
The earliest examples of die casting by aluminium pressure injection - as opposed to aluminium casting by gravity pressure - occurred in the mid-1800s. A patent was awarded to Sturges in 1849 for the first manually operated machine for casting printing type. The process was limited to printer’s type for the next 20 years, but development of other shapes began to increase toward the end of the century. By 1892, commercial applications included parts for phonographs and cash registers, and mass production of many types of parts began in the early 1900s.
Dimensional accuracy and stability - Aluminium die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant.
Strength and weight - Aluminium die casting parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because aluminium die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
Multiple finishing techniques - Aluminium die casting parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.
Simplified Assembly - Aluminium die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.
Aluminium Die Casting Process:
Aluminium die casting vs. permanent mold - Aluminium die casting offers the same advantages versus permanent molding as it does compared with aluminium sand casting.
Aluminium die casting vs. forging - Aluminium die casting produces more complex shapes with closer tolerances, thinner walls and lower finishing costs. Cast coring holes are not available with forging.
Aluminium die casting vs. stamping - Aluminium die casting produces complex shapes with variations possible in section thickness. One casting may replace several stampings, resulting in reduced assembly time.
Aluminium die casting vs. screw machine products - Aluminium die casting produces shapes that are difficult or impossible from bar or tubular stock, while maintaining tolerances without tooling adjustments. Aluminium die casting requires fewer operations and reduces waste and scrap. Each of the metal alloys available for die casting offer particular advantages for the completed part.
Aluminium - This alloy is lightweight, while possessing high dimensional stability for complex shapes and thin walls. Aluminium has good corrosion resistance and mechanical properties, high thermal and electrical conductivity, as well as strength at high temperatures.
Magnesium - The easiest alloy to machine, magnesium has an excellent strength-to-weight ratio and is the lightest alloy commonly die cast.
Copper - This alloy possesses high hardness, high corrosion resistance and the highest mechanical properties of alloys cast. It offers excellent wear resistance and dimensional stability, with strength approaching that of steel parts.
Lead and Tin - These alloys offer high density and are capable of producing parts with extremely close dimensions. They are also used for special forms of corrosion resistance.
Aluminium High Pressure Die Casting
In high pressure die casting , the liquid aluminium is injected at high speed and high pressure into a metal mould.
INTERNATIONAL ALUMINIUM STANDARTS | ||||||||||
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ETIBANK TR | AA | U.K .BS | ISO | RUS | DIN | Werktoff | FRANCE | ITALY | SWEDEN | SWITZERLAND |
ETİAL 5 | 1050A | 1B | AI99,5 | A5 | AI99,5 | 3,0255 | A5 | 4507 | 14-4007 | AI99,5 |
ETİAL 7 | 1070 |
|
| A7 | AI99,7 | 3,0275 |
| 4508 |
|
|
| 1080A | 1A | AI99,8 |
| AI99,8 | 3,128 | A8 | 4509 | 14-4004 |
|
ETİAL 0 | 1200 | 1C | AI99,0 | A0 | AI99 | 3,0205 | A4 | 3567-66 | 14-4010 | AI99,0 |
| 1350 | 1E | AI99,5 |
| E-AI | 3,0257 | A5L |
| E-AL99,5 |
|
ETİAL 20 | 2011 | FC1 | AlCu6BiPb |
| AlCuBiPb | 3,1655 | A-U5PbBi | 6362 | 14-4355 | AlCu6BiPb |
ETİAL 21 | 2014h15 | H15 | AlCu4SiMg |
| AlCuSiMn | 3,1255 | A-U4SG | 3581 | 14-4338 | AlCuSiMn |
ETİAL 22 | 2017 |
|
| Amr6 | AlCuMg1 |
| A-M4G | 3579 |
|
|
| 2117 |
|
|
| AlCu2,5Mg0,5 |
|
|
|
|
|
ETİAL 24 | 2024 |
| AlCuMg1 | 1163 | AlCuMg2 | 3,1355 | A-U4G1 |
|
| AlCu4Mg1,5 |
| 2218 |
|
|
| AlCuMgNi2 |
|
|
|
|
|
ETİAL 30 | 3003 |
| AlMn1Cu | A31M | AlMnCu | 3,0517 | A-M1 | 3568 |
| AlMn |
| 3103 | N3 |
|
| AlMn1 | 3,0515 |
| 7780 | 14-4054 | AlMn |
| 3105 |
|
|
|
|
|
|
|
|
|
ETİAL 31 | 3004 |
|
|
| AlMn1Mg1 | 3,0526 | A-M1G |
|
|
|
| 3005 |
|
|
| AlMn1Mg0,5 | 3,0525 | A-MG0,5 |
|
|
|
ETİAL 50 | 5005 | N41 | AlMg1 |
| AlMg1 | 3,3315 | A-GO-6 | 5764-66 | 14-4106 | AlMg1 |
|
|
|
|
| AlMg2Mn0.8 | 3,3527 |
|
|
|
|
ETAİL 52 | 5052 |
|
| AlMr2 | AlMg2,5 | 3,3523 | A-G2,5C | 3574 |
|
|
| 5754 |
|
|
| AlMg3 | 3,3535 | A-G3M | 3575 |
|
|
| 5056A | N6 | AlMg5 |
| AlMg5 | 3,3555 | A-G5 | 3576 |
|
|
| 5083 | N8 | AlMg4,5Mn |
| AlMg4,5Mn | 3,3547 | A-G4,5MC | 7790 | 14-4140 | AlMg5 |
| 5086 |
|
|
| AlMn4Mn | 3,3545 | A-G4MC |
|
| AlMg4 |
ETİAL 53 | 5154 | N5 | AlMg3,5 | AMr3 | AlMg3,5 | 3,3535 | A-G3 | 3575 |
| AlMg2.7Mn |
| 5251 | N4 | AlMg2 |
| AlMg2Mo3 | 3,3525 | A-G2M | 3574 |
| AlMg2 |
| 5454 | N51 | AlMg3Mn |
| AlMg2,7Mn | 3,3537 | A-G2,5MC | 7789 |
| AlMg2,7Mn |
| 5657 |
|
|
| AlMg0,8Si |
|
|
|
|
|
| 5754 |
|
|
| AlMg3,5 | 3,3535 | A-G3M |
|
|
|
| 6061 | H20 | AlMg1SiCu | AB |
|
| A-GSUC | 6170 |
|
|
ETİAL 60 | 6063 /6060 | H9 | AlMg0,5Si |
| AlMgSi0,5 | 3,3206 | A-GS | 3569 | 14-4104 | AlMgSi0,5 |
ETİAL 61 | 6082 /6351 | H30 | AlSi/MgMn | A35 | AlMgSi | 3,2315 | A-SGM0,7 | 3571 | 14-4212 | AlMgSi0,6 |
ETİAL 64 | 5101A /6463 | 91E | AlMgSi |
| EAIMgSi0,5 | 3,3207 |
| 3570 |
| AlMgSi0,5 |
| 7020 | H17 |
|
| AIZn4,5Mg1 | 3,4335 | A-Z5G | 7791 |
| AlZn4,5Mg1 |
| 7022 |
|
|
| AlZnMgCu0,5 | 3,4345 |
|
|
|
|
| 7075 |
| AlZn6MgCu | B95 | AlZnMgCu1,5 | 3,4365 | A-Z5Gu | 3735 |
| AlZn6MgCu1,5 |
| 7079 |
|
|
|
|
|
|
|
|
|
| 7175 |
|
| B9504 |
|
|
|
|
|
|
ETİAL 110 | 319 | LM4 |
|
|
|
| AS5U3 |
|
|
|
| 355,1 | LM16 | AlSi5Cu1 |
|
|
|
| 3600 |
|
|
ETİAL 120 | B443 /4043 | LM18 | AlSi5 |
| AlSi5 |
|
|
|
|
|
ETİAL 140 | A413,2 | LM6 | AlSi12 |
| AlSi12 | 230 | AS13 | 4514 |
|
|
| A413,1 | LM2 | AlSi12CuFe |
| AlSi12CuFe | 231 | AS12U | 5079 |
|
|
ETİAL 141 | 413 | LM20 | AlSi12Fe |
| GD-AlSi12 |
| AS12 |
|
|
|
ETİAL 145 |
| LM13 |
|
|
|
| AS12UN |
|
|
|
ETİAL 150 |
|
| GAlSi12Cu |
|
|
|
| 5076 |
|
|
ETİAL 160 | B380,1 | LM24 | AlSi8Cu3Fe |
| AlSi8Cu3 | 226 | AS9U3 | 5075 |
|
|
ETİAL 171 | A360,2 |
| AlSi10Mg |
| AlSi10Mg | 239 | AS10G | 3051 |
|
|
ETİAL 175 | F332 | LM26 |
|
|
|
|
|
|
|
|
ETİAL 180 |
| LM2 |
|
|
|
|
|
|
|
|
ETİAL 220 |
| L91 | AlCu4Si |
| AlCu4,5 |
|
|
|
|
|
ETİAL 221 |
| LM11 | AlCuTi |
| AlCu4Ti |
| A-U5GT |
|
|
|
| 308,1 | LM21 | AlSi5Cu3 |
|
| 225 |
| 7364/4 |