Aluminum Castings
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.
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.
The Aluminum Casting Process
Modern 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.
Aluminum is the third most abundantly occurring element in the world and, specifically, the most abundant metal found in the earth's crust. Its refining process is a bit difficult compared to other metals; however, when refined, it can be used efficiently for aluminum castings to produce a quality product. The casting process of aluminum has proven inexpensive and produces a sturdy and reliable product.
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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.
Benefits to Die Casting
- Die casting offers complicated designs with tighter tolerances compared to many other mass manufacturing methods.
- Die castings are created in larger quantities with little to no machining needed.
- Die casting produces parts that are sturdy, dimensionally stable, and of high quality.
- Die castings can be made with surfaces that mimic many different textures.
- Compared to most other casting methods, including sand and permanent castings, die-cast surfaces are smoother.
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.
Benefits of Permanent Mold Casting
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Permanent mold casting is highly useful for manufacturing products in batches since the molded parts have precise dimensions.
- The procedure is well suited for producing intricate pieces with high accuracy.
- This method is suited for manufacturing numerous pieces that are assembled later. It can also rapidly produce accurate and complicated metal castings.
- The permanent mold casting process is frequently less expensive than other metal casting techniques such as die casting.
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.
Benefits of Sand Casting
- Sand casting parts might be as small as a few millimeters and grams or as large as many meters and tons. Only the limitations placed by the handling and supply of molten metal limit the cast's size and weight, enabling large pieces to be made.
- No other method has as many options for sculpting intricate features as sand casting, which yields components closely resembling net shapes.
- As long as an engineering alloy can be melted, practically any form of engineering alloy may be cast.
- Compared to other metal manufacturing techniques, tooling and equipment costs are minimal. Consequently, sand casting is one of the most affordable ways to produce components.
Airset/Nobake Casting
Airset/nobake casting is a type of sand casting involving the creation of 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.
Benefits of Airset/Nobake Casting
- Airset molds do not require heating to harden, unlike shell molds.
- Airset casting can provide a better surface polish and tighter dimensional tolerances compared to other sand casting techniques, such as greensand.
- The chemical bonding agent added to the molding sand makes airset casting special. The casting of the molds can be done fast.
- With extremely few surface flaws, airset casting can offer remarkable consistency from part to part.
How to Choose the Right Casting Method
Based on the required factor, i.e., speed, quality, or strength, here are methods that can be chosen:
- For Speed: In contrast to permanent mold technologies, sand casting offers a large output of parts in a short length of time. Due to the pressured injection process, die casting offers the fastest manufacturing pace.
- Quality of Finish: The smoothest surface finish from a mold is offered by permanent mold casting and die casting.
- For Strength: The strongest material is provided by permanent mold casting in the finished product. Die casting is quite like permanent mold casting, but permanent mold casting is superior to die casting in this case.
- Quantity: Sand casting is the best method when only a few pieces are required. However, die casting might be preferable for higher volumes, considerably more than 100,000.
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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.
Materials (Common Alloys) for Castings
Listed below are some of the most common alloys used by Modern Aluminum Castings Co.:
- Abrasion Resistant Iron
- Aluminum (100, 700 & 800 Series)
- Aluminum-Copper (200 Series)
- Aluminum-Magnesium (500 Series)
- Aluminum-Silicon (300 Series)
- Aluminum-Silicon (400 Series)
- Austempered Ductile Iron
- Carbon Steels
- Cobalt-Base
- Compacted Graphite Iron
- Corrosion Resistant Iron & Steels
- Ductile Gray Irons
- Heat-resistant Iron & Steels
- Copper-Base Alloys
- Lead Low Alloy Steels
- Magnesium Malleable
- Iron Manganese Steels
- Mn/Al-Si Bronze + Cu-Ni Alloys
- Nickel Base
- Red/Yellow Brass/Tin-Bronze
- Superalloys
- Titanium
- Zinc-Base
Industries Served by Different Casting Methods
Following are the industries served by Modern Aluminum Castings Co. through their casting techniques:
- Road Construction
- Soil Pipe/Fittings
- Sanitary/Radiator
- Valves/Pipe Fittings
- Pressure Pipe/Fittings
- Internal Combustion Engines and Turbines/Generators
- Machine Tools
- Metalworking Machinery
- Construction Machinery and Equipment
- Mining Machinery/Equipment
- Farm Machinery/Equipment
- Oil Field Machinery/Equipment
- Conveyors/Conveying Equipment
- Art and Ornamental
- Specialized Industry Machinery
- Pumps and Compressors
- Gears and Power Transmission
- Computer and Office Equipment
- A/C and Heating Equipment
- Home Appliances
- Automobile, Light Truck, and SUV
- Trucks/Buses
- Ship Building and Repair
- Railroad Equipment
Our 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.
Why Choose Modern Aluminum?
Sand, mold, and die are a handful of the techniques available with Modern Aluminum Casting.
There are a variety of reasons to choose Modern Aluminum Casting for your aluminum cast parts. We can provide timely delivery of parts of the highest caliber. In addition, because aluminum can be customized, it can be used for parts with a wide variety of shapes, forms, and sophisticated designs. The finished parts delivered to the customers require little to no machining.
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