The Process of Aluminum Castings. Die casting is probably not a new term for you because everywhere you look; you will see parts and equipments that employed this process for them to be created. Now, aluminum is among the few metals that can be utilized in casting metals. These processes of aluminum casting are the following: permanent mold casting, die casting, investment casting, plaster casting, sand casting (include dry sand and green sand), and continuous casting. Some of the other processes in aluminum casting also include squeeze casting, lost foam, and hot iso-static pressing.

Basically, there are various factors that should be taken to account in the selection of a particular casting process specially in making a detailed aluminum alloy part. Among the most vital factors consist of:

* Quality factor.
* Feasibility
* Cost factor

When talking about feasibility, a lot of aluminum alloy castings may be done using any available methods but for general castings, this process is highly determined by the dimensions or the features of the design. Furthermore, the quality factor is considered as well. Be reminded that the term “quality” when applied to casting would refer to the degree of reliability as well as the levels of mechanical properties which include the strength and ductility. The act of determining the act is also important.

Aluminum castings are considered as easy process as compared to manufacturing other kinds of products but expertise is still needed because not all people can do it properly. In fact, good skill and reliable materials are compulsory in this procedure.

Die Casting Processes with the Use of Zinc Alloy. Die casting is the process by which molten ferrous metal, e.g., zinc, magnesium, copper, lead, tin, aluminum, etc., are molded into cavities and placed under pressure to form. The method of die casting is ideal if the application needed is in large quantity and should be well-detailed and has fine quality. Zinc is a non-ferrous metal that is popularly used for die casting. This is due to the fact that zinc alloys have many characteristics that far exceed other metals. Zinc alloys have high strength and hardness, has high thermal and electrical conductivity, low cost, good finishing characteristics, outstanding fluidity, and excellent corrosion resistance among others.

In the zinc die casting process, two processes are involved, the hot chamber method and the cold chamber method. These two zinc die casting processes make use of various types of metal alloys during the production of parts in the zinc die casting process. The hot chamber method involves the process wherein a steel die is filled with a pool of molten metal, all the time maintaining pressure, until the metal hardens. The second process, the cold chamber method, involves the use of two separate chambers, first to melt, then to hold the melted zinc alloy before it is poured into a shot cylinder and afterwards inject them to the die casting die. Before, the metal alloys used in Zinc die casting processes are tin and lead. The zinc alloy however gained popularity and is now the first choice when it comes to die casting.

What is Magnesium? It is usually depicted as a metal, second only to steel and aluminum in popularity. Aside from that, people don’t know much more about it, even though it has so many uses. So, what is magnesium?

Magnesium, with the chemical symbol Mg, is the ninth most abundant element in the universe by mass, and eleventh within the human body. Its many applications include making components for electronic devices, photoengraving plates for printing, paper manufacturing, and fireproofing wood. Ever heard of mag wheels? Those shiny high-grade car wheels which guys usually drool over in auto shops? They’re not called that because they’re always featured in car magazines – their name comes from what they’re made out of, which is magnesium.

One of the current major uses of the element is in die casting. Because of its light weight, magnesium is one of the most commonly used metals for this purpose, as compared to zinc and aluminum.

A lot of compounds can be made with magnesium, and these compounds, along with magnesium in its purest form, are used over a wide variety of industries. What is magnesium? It is a very important and useful element – it’s not just a third place metal behind steel and aluminum.

This chart shows the metals used for die casting. The four metals shown are the most common materials used in die casting alloys.

Other Die Casting Materials Comparison