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Cast Aluminium Components Aluminum Permanent Mould Casting Proces

Categories Cast Aluminium Parts
Brand Name: Non-Standard
Model Number: Customized
Place of Origin: China
MOQ: 1 Ton
Price: quote according to different drawing technique requirements
Payment Terms: T/T, L/C
Supply Ability: 300 Tons every month
Delivery Time: within 60 days
Packaging Details: Plywood crate
Material: ZL101, ZL102 etc.
Process: Aluminum Permanent Mould Process
Machining: CNC machining
Surface: Natural Color
Packing: Plywood Crate
Heat Treatment: T6 Treatment
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Cast Aluminium Components Aluminum Permanent Mould Casting Proces

Cast Aluminium Components Aluminum Permanent Mould Casting Proces


Product Description and Process
Aluminum Permanent Mould Casting Process ZL101 102 T6 Treatment Aluminum Foundry

Production process: green sand casting process, pre-coated sand casting process
Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.
Surface treatment process: anodic oxidation, Dacromet coating, powder coating, etc.

Product Material and Uses
Normally produce with ZL101, ZL101A, ZL102, ZL104, ZL106, ZL107, ZL109, ASTM A356 T6, A319, A413, LM6, LM20, LM25, etc.

The aluminum casting products are widely used for electronic industry, auto-car parts, railway parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.





GRAVITY DIE CASTING
Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminum, Zinc and Copper Base alloys.
The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.
GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.

There are three key stages in the process
1 The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
2 Molten metals are poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould “down sprue” that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
3 Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.

Advantages
Good dimensional accuracy
Smoother cast surface finish than sand casting
Improved mechanical properties compared to sand casting
Thinner walls can be cast compared to sand casting
Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
Steel pins and inserts can be cast in to the part
Faster production times compared to other processes.
Once the tolling is proven, the product quality is very repeatable.
Outsourced Tooling setup costs can be lower than UK sand casting.
ALUMINUM CASTING METALS
Aluminum castings are lightweight and able to withstand the highest operating temperatures of all die cast alloys.
Aluminum Alloy Characteristics:
High operating temperatures
Outstanding corrosion resistance
Lightweight
Very good strength and hardness
Good stiffness and strength-to-weight ratio
Excellent EMI and RFI shielding properties
Excellent thermal conductivity
High electrical conductivity
Good finishing characteristics
Full recyclability
Aluminum’s strength, corrosion resistance, and heat dissipating properties offer mechanical designers significant advantages. And our proprietary Thin Wall Aluminum Technology has made aluminum die casting an option for even more applications.

A380 Aluminum Alloy
The most popular alloy for aluminum die casting is A380. We use A380 because it has demonstrably the best combination of physical and mechanical properties for casting, including being lightweight, very strong at high temperatures and corrosion resistant. A380 is also very good at retaining dimensional stability even with complex shapes and thin walls and offers high electrical and thermal conductivity.
A383 Aluminum Alloy
Another option for die casters is to use A383 aluminum alloy. This is alloy is typically only used when you are forming intricate components and require very specific die-filling characteristics. While it doesn’t share all the properties of A380, it does offer higher strength at high temperatures with less chance of cracking under heat.
A360 Aluminum Alloy
A360 is harder to cast than A380, which is why many die casters avoid it. However, it does offer higher strength at high temperatures, better ductility and higher corrosion resistance, so you may want to consider this alloy depending on your casting abilities and needs.
A360 vs. A380 v. A383
To summarize the differences between the three types of casting alloys as outlined above, A360 has the best pressure tightness, high-temperature strength and corrosion resistance of the three alloys.
A380 is also highly corrosion-resistant but more cost-effective and easier to work with than A360, so this is the one you would use most commonly if you have budgetary concerns to consider and don’t need the highest levels of corrosion resistance or pressure tightness.
A383 is a modified A380 alloy you would only use if you need precise die filling that you are not getting from your A380 alloy, as it is not as durable as A380.

319 Aluminum Sand Castings
Aluminum alloy 319 is a 6% Si and 3.5% Cu alloy with 1.0 Fe maximum. It has excellent casting and machining characteristics. Corrosion resistance and weldability are very good. Mechanical properties are good in both the heat-treated (T5) and non-heat treated conditions.
The anodized color is generally gray with a brown cast depending on the amount and ratio of silicon and copper.
Typical applications for sand casting 319.0 are a wide variety of structural castings for engine parts, engine crankcases, gas and oil pans, and general commercial applications.

Typical Mechanical Properties

AlloyTemperUltimate Tensile (ksi)Yield Strength (ksi)Brinell Hardness (500 Kg)Shearing Strength (ksi)
319.0F27187022
355.0T635258028
356.0T633247026
A356.0T6403075
A357.0T646368540
535.0 (Almag 35)F40207027
713.0 (Tenzaloy)F or T5342375265


Chemical Composition (%)

AlloyCu.Si.Mg.Zn.OtherAl.
319.03.56---Bal.
355.01.350.5--Bal.
356.0-70.3--Bal.
A356.0-70.3-Fe 0.2 maxBal.
A357.0-70.6-Ti 0.1 Be 0.06Bal.
535.0 (Almag 35)--6.9-Be 0.005Bal.
713.0 (Tenzaloy)0.7-0.47.5-Bal.


Typical Applications

AlloyApplication
319.0Engine crankcases, gas and oil tanks, engine oil pans, engine parts.
355.0Air compressor pistons, printing press, water jackets & crankcases.
356.0Flywheel castings, automotive transmission cases, oil pans, pump bodies.
A356.0High strength airframe and space frame structural parts, machine parts, truck chassis parts, high velocity blowers and impellers.
A357.0High strength aerospace castings.
535.0 (Almag 35)High strength alloy used for electronic equipment, aircraft components and parts requiring a high degree of dimensional stability and strength. Superior ductility makes it an excellent replacement for malleable iron. No heat treat required.
713.0 (Tenzaloy)Automotive parts, trailer parts, pumps & mining equipment.


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