When you are looking to manufacture the various components of your product, you may find that you are presented with the option of selecting aluminum die casting, sand casting, or permanent mold casting as the manufacturing process to use. What differentiates these various processes from one another, and how can you determine which one is best for you? Continue reading to find out more.
What Is Aluminum Die Casting?
Liquifying an aluminum alloy is the first step in the die casting process for aluminum. Once the alloy is liquid, the molten metal is then forced under high pressure into a mold. The die is an iron or steel mold in the shape of the component that you want to produce. As soon as the metal has reached its final state, the casting shot will be extracted from the mold so that it can be used in the production of the subsequent unit. The speed with which we can prepare the machine for the next unit, which can be as little as one minute, is one of the significant advantages of this type of process for manufacturing metal products. Because of this, we are able to generate extremely high production runs.Die casting requires extremely robust tooling that can withstand high temperatures without breaking
What Is the Difference Between Sand Casting and Permanent Mold Casting?
The primary distinction between permanent mold castings and sand castings is the kind of material that is used to make the mold. Sand castings are very comparable to permanent mold castings. You can make a permanent mold out of steel or cast iron, and it can have multiple cavities so that you can make different types of parts. This feature is particularly useful given that the mold is intended to be used more than once. These molds are only suitable for use with metals that are not ferrous.
Sand mold castings use a similar concept, but the mold is made from a mixture of sand and other materials. Once the casting process is finished, the mold is broken apart to reveal the part that was cast. After that, the sand is recycled and used for making additional casting molds. This method of casting has very low tooling costs; however, because it takes a very long time to set up again, it is not ideal for use in situations involving short timeframes or high volumes of production.
Which Method, Permanent Mold Casting/Sand Casting, or Aluminum Die Casting Should I Use?
Aluminum die casting has a number of advantages in comparison to other casting methods, such as sand casting and permanent mold casting. Die casting allows for extremely close dimensional tolerances and requires very little post-machining work. Die casting in aluminum is an excellent choice for high-volume production runs because it enables the rapid production of a large number of parts while maintaining excellent part consistency. You can also make components that have thinner walls and surfaces that are more polished.
Casting with a Permanent Mold
Casting in a permanent mold provides you with a mold for multiple parts that you can reuse time and time again while maintaining a high level of surface finish and dimensional accuracy. Casting with a permanent mold is another option for those seeking high production rates. Die casting and other processes require a mold that is permanent in order to work with non-ferrous metals; this is also the case with casting. Because of the high costs associated with making the permanent mold die (which are comparable to the costs of die casting but slightly less expensive), as well as the relatively short life of the mold, using permanent mold casting is typically not a cost-effective option when casting components for a project that will last for an extended period of time.
Casting in the Sand
Sand casting, which typically makes use of silica as the molding sand but can also use other types of sand, such as chromite or zircon, is fantastic if you are looking to reduce tooling costs because it is relatively inexpensive to make a sand cast mold in comparison to a die-cast mold. Sand casting can be used to make a wide variety of things, including:It is also a great option to go with if you are making a large variety of parts in very small quantities for a single production run. Sand casting, on the other hand, is not a cost-effective method in terms of the cost per part for larger production runs because it takes so much time to reset the mold.
Die casting in aluminum is typically the best option for businesses that require a consistent supply of highly specialized components because it allows for greater customization. The production of the die itself represents the majority of the cost associated with aluminum die casting. When compared to processes that use sand or permanent molds, however, once we have manufactured the die, it is relatively simple and cost-effective to produce a large number of long-lasting, complex parts in a short amount of time.