The Aluminum Casting Process


Aluminum Cast ComponentsModern Aluminum Casting offers a variety of methods in the casting process that include sand, mold, and die to name a few. Each of the various methods have their benefits and produce high quality parts. When making a choice of the type of casting, several factors have to be considered such as the size of the part, quantity required, surface finish, and the requirements of dimensional accuracy.

There are many reasons to choose aluminum casting by Modern Aluminum Casting for your aluminum cast parts. We are able to offer high quality parts quickly and make them immediately available. The aluminum castings processes are inexpensive and produce parts that are very strong and sturdy. Seeing as aluminum is customizable, we can offer parts in many shapes, forms and any type of complex design. Modern Aluminum Casting offers finished parts that require very little machining since the parts come out of the mold in nearly perfect shape.

The casting process begins with you and your design. In most cases, designing is a collaboration between Modern Aluminum Casting and our customers. Using highly advanced computer software, expert personnel develop the proposed cast to be produced to your specifications. A temporary mold is sent on to the shop for the purpose of making a prototype for you to inspect and approve. Once accepted, a permanent casting is created for production in technically advanced facilities.

Different types of aluminum casting

All aluminum that is cast is made from aluminum and added alloy considering aluminum by itself is not very resilient. When making the decision for the type of casting method, the choice depends on the type of part as well as the strength required, its size and the quantity. Once the design is accepted, one of the following processes is available to be chosen for production of your part, though what is listed is a small sample of what we can offer.

Die casting – Die casting uses pressure to force molten aluminum into a die. This procedure is used for mass production of parts and requires very little finishing and machining. The main cost of die casting is in the tooling process and the creation of the die. There are two types of die casting: low and high pressure where high pressure requires a complicated die and low pressure uses a simple one.

Permanent mold casting – Permanent mold casting uses steel or other metals to create the mold and cores. It is used to make repeatable parts that are consistent throughout a run. The molten aluminum is poured into the mold where it cools very quickly to create a very consistent microstructure that improves its mechanical properties.

Sand casting – In the sand casting process, a mixture of sand is packed around the desired shape of the product. The sand pattern is slightly larger than the final product to allow for shrinkage during cooling. Sand casting is a very economical method for casting aluminum given that the sand can be used multiple times to produce a variety of parts. It is perfect for large molds or parts that are highly detailed. The tooling process is inexpensive and is designed for the production of specialized or custom parts.

Airset/nobake casting – Airset/nobake casting is a type of sand casting involving the creation a mold from chemically treated sand. It offers a better surface finish on the final product and a tighter dimensional tolerance. The mold for this sand method can be created quickly, but the cast part may have a slightly rougher finish. A benefit of airset/nobake casting is the consistency from part to part with few surface defects.

These four examples are just a few of the many methods Modern Aluminum Casting has available to mold and shape aluminum. The types and designs of our aluminum parts are determined by your requirements and specifications.

Types of aluminum alloys

Modern Aluminum Casting offers the highest quality aluminum that has been combined with an alloy to increase its strength. Since aluminum is a lightweight metal and is three times lighter than iron, it has to be mixed with alloys for the manufacturing process. Though it has a low density, it is still very strong with a tensile strength of 70 to 700 MPa (strength). It can be easily machined and is malleable enough to be extruded. To add to its strength and resiliency, it is alloyed with various metals such as silicon, iron, copper, magnesium, zinc, and several others.

Due to the fact that pure aluminum is ductile, in the manufacturing process, it has other metals added to increase its strength. The combination creates a very strong, corrosion resistance, and inexpensive product. By working with Modern Aluminum Casting, we can help you to carefully choose the proper alloy then have it adjusted and fine-tuned for any purpose.

The Aluminum Association Inc. registers the various aluminum alloys beginning with series 1000, which is 99% aluminum, to 8000. The higher the number the stronger is the mixture of aluminum and the alloy. The categorization is by thermal and mechanical treatment and the alloy that has been added to the aluminum. The type of alloy determines the characteristics and application of the final product.

The Request for Quote Process

Modern Aluminum Casting customers have easy access to our RFQ process that is conveniently available online with sufficient room to describe your project or projects as well as the timeline needed for its completion. Our staff of experts are available to work closely with you in the design and completion of your order. Modern Aluminum Casting is dedicated to providing products that meet and exceed your expectations and requirements.

With over 100 years of experience in the casting industry, Modern Aluminum Casting has the facilities and staff to meet any requirements. The process begins with you, the customer, by entering your specifications into our RFQ form. You will be immediately contacted by one of our experts who can walk you through the process of designing, casting, and producing any type of aluminum and metal casting.

Modern Aluminum Casting offers the most up to date equipment and methods to provide our customers with exceptional parts at reasonable prices. Our years of success and experience is proof of our quality.

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Modern Aluminum Castings Co., Inc.
Phone: 812.232.0007
FAX: 812.232.0009
Toll Free: 800.467.6252
email: sales@modernaluminum.com

1400-1500 N. 14th St.
Terre Haute, IN 47807 

Rated A-1 by Dunn & Bradstreet
Member: American Foundry Society