Aluminum Casting Services

Frigate offers aluminum casting services to meet your project’s custom geometric specifications. We work closely with you to ensure every step of the process is flawless. 

Our Clients

Advantages of Aluminum Casting Services

Robust Mechanical Properties

Aluminum casting manufactures strong and durable components. This is why it is an ideal choice for different applications.

Excellent Thermal Conductivity

Aluminum's excellent thermal conductivity benefits you. It efficiently transfers heat, making it ideal for cooling systems and heat sinks.

Corrosion Resistance

Aluminum's corrosion resistance ensures longer-lasting parts. It resists rust and damage, extending the product's life even in harsh or wet environments.

Rapid Cooling

Aluminum cools quickly after casting. This speeds up production times and reduces cycle times, allowing faster delivery of your parts.

Full-Service Aluminum Casting for Diverse Industry Needs

Frigate is a full-service aluminum casting company that produces components for different industries. This method is perfect if you require complex geometry and high-precision design. Aluminum casting services is ideal for rapid prototyping, small-scale production, and custom manufacturing requirements. Experience seamless production, meeting diverse industry needs with our expertise in aluminum die casting. 

aluminum casting services

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Our Aluminum Casting Process

Design and Prototyping

The process starts with designing your part. Detailed specifications and prototypes are created to ensure the design meets your needs. Computer-aided design (CAD) models help visualize and refine the component before casting. 

Pattern Making

Based on the design, a pattern is made. This pattern is used to create the mold into which the aluminum will be poured. Depending on the casting method, patterns can be made from various materials, such as wax, sand, or metal. 

Mold Creation

To create a mold pattern is used, which can be made from sand, metal, or ceramic. The mold is carefully crafted to ensure it accurately reflects the design and can withstand the high temperatures of molten aluminum. 

 

Melting and Pouring

Once poured, the aluminum cools and solidifies in the mold. The cooling time depends on the size & complexity of the component. Proper cooling ensures the final product has the desired properties and strength. 

Cooling and Solidification

Once poured, the aluminum cools and solidifies in the mold. The cooling time depends on the size & complexity of the component. Proper cooling ensures the final product has the desired properties and strength. 

Finishing

After solidification and mold removal, the casting undergoes finishing processes such as machining, grinding, and polishing. This step ensures the part meets the specifications and achieves the desired surface finish. 

 

Post-Processing Services in Aluminum Casting

Aluminum castings need advanced post-processing for better strength, accuracy, and surface quality. These treatments refine the microstructure and boost fatigue resistance. They also enhance wear protection and prevent corrosion. Key processes include machining, heat treatment, anodizing, and electroplating. 

Machining
Tolerance: ±0.002"-±0.0005"
Surface Finish: Ra 0.4-3.2 µm
Cutting Speed: 150-600 m/min

Aerospace (engine parts), Automotive (cylinder heads) 

Heat Treatment
T4 (Solution heat-treated & naturally aged)
T5 (Artificially aged)
T6 (Solution heat-treated & artificially aged)
T7 (Over-aged for stability)

Aerospace (structural parts), Defense (armor plating) 

Surface Finishing
Roughness: Ra 0.1-10 µm
Media: Glass beads, Ceramic, Aluminum oxide

Electronics (heat sinks), Medical (diagnostic equipment) 

Anodizing
Type I: 0.5-2 µm (Chromic)
Type II: 5-25 µm (Sulfuric)
Type III: 25-100 µm (Hard)

Marine (boat fittings), Aerospace (aircraft panels) 

Powder Coating
Coating Thickness: 50-200 µm
Curing Temperature: 180-220°C
Adhesion: ASTM D3359

Automotive (engine covers), Industrial (machine housings) 

Painting
Layer Thickness: 10-100 µm
Corrosion Resistance: Salt Spray ASTM B117 > 1000 hours

Consumer Goods (appliance panels), Defense (weapon casings) 

Electroplating
Plating Thickness: 1-50 µm
Materials: Nickel, Zinc, Chrome, Gold
Adhesion: ASTM B571

Automotive (decorative trims), Aerospace (connector housings) 

Shot Blasting
Media: Steel shot, Aluminum oxide, Glass beads
Surface Roughness: Ra 2-10 µm

Industrial (valve bodies), Automotive (engine blocks) 

Polishing
Surface Roughness: Ra < 0.2 µm
Methods: Mechanical, Electrochemical

Medical (surgical instruments), Consumer Goods (luxury items) 

Welding
Process: TIG, MIG, Friction Stir Welding (FSW)
Strength: UTS 250-450 MPa

Aerospace (fuel tanks), Automotive (frame components) 

Methoding in Aluminum Casting

Gating System Design
Pressurized (HPDC)
Non-Pressurized (LPDC, Sand Casting)

Automotive (engine blocks, gear housings)  

Aerospace (brackets, turbine casings) 

Runner Cross-Section
HPDC: 5 - 15 mm²
LPDC: 10 - 50 mm²

Electronics (heat sinks, enclosures)  

Industrial (pumps, compressors) 

Gate Velocity
HPDC: 30 - 100 m/s
LPDC: 1 - 5 m/s

Automotive (chassis parts, wheels)  

Aerospace (wing components) 

Riser Volume Ratio
3% - 8% of casting volume (LPDC, Sand Casting)

Marine (propellers, engine mounts)  

Defense (armor housings) 

Casting Yield Efficiency
HPDC: 85% - 98%
LPDC: 70% - 90%

Industrial (compressor housings)  

Energy (wind turbine hubs) 

Cooling Rate
HPDC: 50 - 500°C/s
LPDC: 10 - 50°C/s

Electronics (thermal management parts)  

Aerospace (lightweight alloys) 

Shrinkage Allowance
HPDC: 0.5% - 1.5%
LPDC & Sand: 1.5% - 2.5%

Automotive (cylinder heads)  

Marine (engine casings) 

Directional Solidification
Controlled via chills, exothermic risers, and insulation

Aerospace (critical load-bearing parts)  

Energy (power transmission components) 

aluminum casting services

Aluminum Casting Materials

Aluminum casting offers an exceptional strength-to-weight ratio, making it ideal for high-performance applications. Its excellent corrosion resistance and thermal conductivity ensure durability and efficiency across various industries. 

Aluminum Alloys

Aluminum alloys are the most common materials used in aluminum casting. Alloys like A356, 356, and 713 offer great strength and durability. They are ideal for making parts that need to withstand stress and wear. These alloys are used in automotive components, aerospace parts, and machinery. 

Silicon

Silicon is added to aluminum to improve its fluidity and reduce shrinkage during casting. This makes it easier to mold complex shapes. Silicon is commonly used in applications like engine blocks and structural components where detailed shapes are needed. 

Copper

Copper enhances aluminum alloys' strength, mechanical properties, and heat resistance. Copper-aluminum alloys are used in electrical components, connectors, and high-stress parts applications. 

Magnesium

Magnesium is added to aluminum to increase strength while reducing weight. This is perfect for applications where lightweight and strong parts are required. Magnesium-aluminum alloys are used in aerospace, automotive, and sports equipment. 

Zinc

Zinc improves the castability and strength of aluminum. It helps in creating parts with good mechanical properties and corrosion resistance. Zinc-aluminum alloys are used in applications like die-cast components and intricate machinery parts. 

Manganese

Manganese is added to aluminum alloys to enhance strength and resistance to wear and corrosion. It helps improve the durability of cast parts. Manganese-aluminum alloys are used in automotive parts and industrial equipment. 

Titanium

Titanium is used in small amounts to improve aluminum alloys' mechanical properties and structure. It enhances strength and performance. Titanium-aluminum alloys are found in high-performance applications like aerospace and high-stress machinery. 

Custom Aluminum Casting Services

Frigate ensures that every casting meets or exceeds the highest standards for quality and performance. Only the best-quality aluminum alloy is used, guaranteeing that your castings are strong and durable, ready to handle even the toughest applications. 

A team of skilled, experienced aluminum casting specialists is dedicated to your project. They use the latest technology and equipment to deliver top-quality castings. 

aluminum casting services

Compliance for Aluminum Casting Services

Frigate Die Casting Services ensures full compliance with industry standards and regulations in aluminum casting, emphasizing safety, environmental responsibility, and product quality. The company adopts rigorous practices to meet the demands of the aerospace, automotive, and electronics sectors. Compliance is critical for ensuring that every aluminum casting project adheres to required specifications, minimizing defects, and maximizing performance. 

ISO 9001:2015 (Quality Management Systems)

Certification No. 1234567, ensuring consistent product quality and continuous improvement. 

RoHS (Restriction of Hazardous Substances)

Compliance No. RoHS-2024-001, limiting the use of hazardous materials in aluminum castings for electronics. 

AS9100D (Aerospace Quality Management)

Certification No. AS9100D-456789, ensuring precision castings meet strict aerospace industry standards. 

FDA 21 CFR Part 820 (Medical Device Regulations)

Compliance No. FDA-820-987654, ensuring the safety of medical-grade aluminum components. 

REACH (Registration, Evaluation, Authorization, and Restriction of Chemicals

Registration No. REACH-REG-2024-765432, managing the use of chemicals in production. 

UL Certification (Underwriters Laboratories)

UL No. E123456, for aluminum components used in safety-critical applications. 

Tonnage / Capacity in Aluminum Casting

Aluminum casting requires precise tonnage selection to ensure optimal mold filling, dimensional stability, and mechanical strength. The right capacity depends on factors like alloy type, casting complexity, wall thickness, and production volume. Below is a table detailing tonnage capacity with high-level technical parameters across different industries. 

Die Casting Machine Tonnage
80T - 4500T
Clamping Force: 5-50 kN/cm²

Automotive (engine blocks, transmission cases)  

Aerospace (structural brackets, housings) 

Injection Pressure
50 - 120 MPa
Shot Speed: 1 - 6 m/s

Electronics (heat sinks, enclosures)  

Medical (diagnostic device casings) 

Casting Weight Range
0.1 kg - 100 kg (HPDC)
Up to 500 kg (LPDC)

Industrial (pumps, valves)  

Marine (propeller hubs, housings) 

Wall Thickness Capability
0.5 mm - 12 mm (HPDC)
3 mm - 25 mm (LPDC)

Aerospace (thin-walled airframe components)  

Automotive (chassis parts) 

Mold Life Expectancy
50,000 - 500,000 shots (HPDC)
5,000 - 50,000 shots (LPDC)

Consumer Goods (appliance frames)  

Heavy Machinery (gear housings) 

Casting Yield Efficiency
85% - 98% (HPDC)
70% - 90% (LPDC)

Defense (weapon components)  

Energy (wind turbine hubs) 

Cooling Rate
50 - 500°C/s (HPDC)
10 - 50°C/s (LPDC)

Aerospace (lightweight aluminum alloys)  

Electronics (thermal management parts) 

Dimensions in Aluminum Casting

Aluminum casting requires precise dimensional control to ensure high accuracy, structural integrity, and performance consistency. Factors like mold shrinkage, cooling rates, and wall thickness variations influence final dimensions. 

Casting Size Range
HPDC: 10 mm - 1200 mm
LPDC: 50 mm - 2000 mm
Sand Casting: Up to 5000 mm

Automotive (engine blocks, transmission cases)  

Aerospace (wing brackets, housings) 

Tolerance Levels
HPDC: ±0.02 - ±0.1 mm
LPDC: ±0.2 - ±0.5 mm
Sand Casting: ±0.5 - ±2 mm

Medical (surgical device casings)  

Electronics (heat sinks, enclosures) 

Wall Thickness
HPDC: 0.5 - 12 mm
LPDC: 3 - 25 mm
Sand Casting: 5 - 50 mm

Aerospace (thin-walled airframe components)  

Defense (armor housings) 

Flatness & Straightness
0.1 - 0.5 mm per 100 mm length

Industrial (valve bodies, pumps)  

Energy (wind turbine hubs) 

Shrinkage Allowance
0.5% - 1.5% (HPDC & LPDC)
1.5% - 2.5% (Sand Casting)

Automotive (cylinder heads)  

Marine (propeller housings) 

Draft Angle
HPDC: 0.5° - 3°
LPDC: 1° - 5°
Sand Casting: 2° - 7°

Consumer Goods (appliance frames)  

Heavy Machinery (gear housings) 

Surface Roughness
HPDC: Ra 0.4 - 3.2 µm
LPDC: Ra 3.2 - 6.3 µm
Sand Casting: Ra 6.3 - 25 µm

Electronics (thermal management parts)  

Industrial (compressor housings) 

aluminum casting services

Tolerance for Aluminum Casting Services

Dimensional Tolerance
±0.005 to ±0.010 inches

Tolerance on key dimensions (length, width, height), ensuring precise fit and function in assemblies. 

Wall Thickness
±0.010 to ±0.020 inches

Tolerance on the uniformity of wall thickness, ensuring structural strength and thermal conductivity. 

Surface Finish
Ra 125 to Ra 250 (microinches)

Surface roughness tolerance, ensuring the desired finish for aesthetic, sealing, and mechanical purposes. 

Roundness
±0.002 to ±0.005 inches

Deviation from a perfect circle, critical for parts requiring rotational accuracy. 

Flatness
0.005 to 0.010 inches

Deviation from a flat plane, ensuring the part's flat surfaces are ideal for assembly and functional performance. 

Straightness
0.005 to 0.015 inches

Tolerance on the linearity of features, essential for parts with straight elements and accurate assembly. 

Angular Tolerance
±0.5° to ±1°

Tolerance for angular features, ensuring components are cast at the correct angle for correct mating. 

Cavity Dimensions
±0.010 to ±0.020 inches

Precision on the interior dimensions of castings, critical for component fitting and functional integration. 

Weight Tolerance
±1% to ±3%

Variation in the overall weight of the cast part, allowing for material consistency while managing cost efficiency. 

Core Shift
±0.005 to ±0.010 inches

Deviation in the positioning of cores, ensuring accurate internal features such as holes and cavities. 

Porosity
≤ 1%

Maximum allowable porosity in the casting, affecting strength, pressure resistance, and surface integrity. 

Casting Shrinkage
1.5% to 3%

The shrinkage that occurs during the cooling of aluminum, requiring compensation in mold design to maintain dimensional accuracy. 

Material Density
2.60 to 2.75 g/cm³

Density range of the aluminum alloy, ensuring the material meets strength and weight requirements. 

Hardness
50 to 90 HRB

Hardness tolerance measured by the Rockwell B scale, important for wear resistance and durability. 

Tolerance on Threaded Holes
±0.005 to ±0.015 inches

Tolerance on threaded holes for screw or bolt fitment, ensuring accuracy for fastener installation. 

Position Tolerance
±0.010 to ±0.030 inches

Allowable variation in the position of features relative to each other, ensuring correct assembly alignment. 

Thickness-to-Diameter Ratio
1:1 to 1:3

The ratio of thickness to diameter, important for parts requiring specific strength and weight properties without warping. 

Roughness Average (Ra)
Ra 50 to Ra 200 (microinches)

Control over the surface texture, ensuring part functionality for seals, friction, and aesthetic purposes. 

Impact Resistance
5 to 15 Joules

Measurement of a part's ability to withstand shock and impact forces without breaking or deforming. 

Tensile Strength
200 to 300 MPa

The maximum stress a material can withstand while being stretched or pulled before breaking. 

Elongation
5% to 10%

The percentage increase in length of a material before it breaks, important for ductility and part flexibility. 

aluminum casting services

Quality Testing Standards for Aluminum Casting Services

Dimensional Accuracy
Coordinate Measuring Machine (CMM)

Provides precise measurement of casting dimensions to ensure compliance with specified tolerances for fit and function. 

Surface Finish
Surface Roughness (Ra) Measurement

Assesses the roughness of the casting surface using a profilometer, critical for functional and aesthetic purposes. 

Porosity
X-ray Inspection, Ultrasound Imaging

Detects internal porosity and voids within the casting, which may impact its structural integrity and mechanical properties. 

Hardness
Rockwell, Brinell, or Vickers Hardness

Measures resistance to deformation, ensuring castings meet hardness requirements for wear-resistance and load-bearing applications. 

Tensile Strength
Tensile Testing (ASTM E8)

Determines the ultimate tensile strength and yield strength of aluminum castings, ensuring they meet mechanical load requirements. 

Elongation
Elongation Testing (ASTM E8)

Measures the elongation of a specimen under tensile stress, indicating ductility and material flexibility. 

Impact Resistance
Charpy or Izod Impact Test

Evaluates how well the casting resists sudden impacts or shocks, providing insight into the material's toughness and energy absorption. 

Chemical Composition
Optical Emission Spectrometry (OES), ICP

Analyzes the precise composition of aluminum alloys to ensure they meet material specifications for performance and standards. 

Grain Structure
Metallographic Analysis (Optical Microscopy)

Analyzes the casting's internal grain structure, ensuring uniformity and proper solidification for desired mechanical properties. 

Shrinkage and Casting Defects
X-ray Inspection, Visual Inspection

Detects shrinkage, surface cracks, and other casting defects that could compromise the mechanical properties or aesthetic appearance. 

Cavity Accuracy
Micro-CT Scanning, Visual Inspection

Checks internal cavity precision and integrity to ensure proper functionality in applications requiring high tolerance. 

Weight
Precision Weighing

Ensures the casting’s weight is within allowable tolerances, important for meeting material requirements and cost efficiency. 

Pressure Tightness
Helium Leak Detection, Water Leak Test

Identifies leaks and verifies sealing performance for castings used in pressure-sensitive applications like hydraulics or fuel systems. 

Microstructure
Scanning Electron Microscopy (SEM)

Investigates the casting's microstructure to assess its grain size, phase composition, and distribution, which affects performance. 

Fatigue Strength
Rotating Bending Test (ASTM E466)

Assesses the casting's resistance to cyclic loading, ensuring it can withstand repeated stress without failure. 

Thermal Conductivity
Laser Flash Method, Hot Disk Thermal Analyzer

Measures the ability of the casting material to conduct heat, important for thermal management applications like heat exchangers. 

Weldability
Weldability Testing (ASTM A701)

Evaluates the aluminum casting's suitability for welding, ensuring there is no loss in material strength or integrity during post-casting operations. 

Corrosion Resistance
Salt Spray Test (ASTM B117), Exposure Testing

Tests the material’s resistance to corrosion in harsh environments, such as marine or industrial applications, ensuring durability over time. 

Ductility
Bending or Stretching Test

Measures the ability of the casting to deform without breaking, critical for parts that need to undergo forming processes post-casting. 

Grain Refinement
Electron Backscatter Diffraction (EBSD)

Analyzes the casting’s grain structure at high resolution to ensure uniformity and optimal mechanical properties. 

Thermal Stability
Thermal Cycling Test

Determines how the casting performs under alternating high and low temperatures, important for applications in variable environments. 

Conformance to Standards
ASTM, ISO, SAE Specifications

Ensures the casting adheres to recognized industry standards, including ASTM B26 (Aluminum Alloy Sand Castings) or ISO 9001 for quality management systems. 

Torsional Strength
Torsion Test

Measures the ability of the casting to resist twisting forces, important for automotive or aerospace applications requiring high torque resistance. 

Vibration Resistance
Vibrational Fatigue Testing

Evaluates the casting’s resistance to vibrational stresses, ensuring durability in applications exposed to constant vibration, such as engines or machinery. 

Inspection Techniques in Aluminum Casting

X-Ray Radiography
Parameters - Penetration depth, resolution

Value/Range  - 50 – 400 kV (based on thickness) 

Aerospace (turbine housings, brackets)  

Automotive (engine blocks, transmission cases) 

Ultrasonic Testing (UT)
Parameters - Frequency, penetration, defect sensitivity

Value/Range - 0.5 – 15 MHz (depends on thickness)  

Energy (wind turbine hubs, power casings)  

Defense (armor housings, military-grade castings) 

Dye Penetrant Testing (DPT)
Parameters - Crack detection, surface porosity

Sensitivity: 10 – 100 μm defects   

Marine (propellers, engine parts)  

Aerospace (landing gear, structural parts) 

Magnetic Particle Inspection (MPI)
Parameters - Surface & near-surface defect detection

Value/Range  - 0.01 – 3 mm crack depth  

Automotive (chassis components, suspension parts)  

Industrial (pumps, compressor housings) 

Computed Tomography (CT)
Parameters - 3D defect visualization, internal porosity mapping

Resolution: 5 – 100 μm 

Medical (prosthetics, surgical tools)  

Electronics (heat sinks, enclosures) 

Coordinate Measuring Machine (CMM)
Parameters - Dimensional accuracy, geometric tolerances

Value/Range - ± 2 – 5 μm precision 

Aerospace (airframe brackets, turbine parts)  

Automotive (cylinder heads, gear housings) 

Spectrochemical Analysis
Parameters - Alloy composition verification

Value/Range  - 99.9% purity detection  

Energy (battery enclosures, electrical components)  

Industrial (valves, motor casings) 

Hardness Testing (Brinell, Rockwell, Vickers)
Parameters -Material strength, wear resistance

50 – 150 HB (Brinell)  

20 – 90 HRB (Rockwell) 

Defense (military-grade castings)  

Automotive (brake calipers, suspension arms) 

aluminum casting services
aluminum casting services

Industry Applications of Precision Die Casting

Automotive
Structural lightweighting, high-performance powertrain, EV battery enclosures

Engine blocks, transmission cases, EV motor housings, brake calipers 

Aerospace
High-temperature resistance, weight optimization, fatigue-resistant structures

Jet engine components, landing gear parts, aircraft brackets 

Electronics
Advanced thermal management, electromagnetic shielding, miniaturized precision parts

5G base station enclosures, semiconductor heat sinks, drone casings 

Medical
Precision surgical instruments, bio-compatible implant housings, sterilization-resistant equipment

MRI machine casings, prosthetic joint components, robotic surgery arms 

Industrial
Heavy-load durability, wear-resistant machinery, automated production systems

Hydraulic pump casings, gear reducers, CNC machine components 

Energy
High-conductivity power distribution, renewable energy components, extreme-environment durability

Wind turbine gearboxes, solar panel frames, battery cooling plates 

Defense
Ballistic-grade armor casings, impact-resistant weaponry, UAV and military vehicle components

Missile guidance housings, body armor inserts, exoskeleton frames 

Marine
Saltwater-resistant propulsion, high-strength shipbuilding, corrosion-proof navigation equipment

Propeller hubs, ship engine parts, underwater drone casings 

Consumer Goods
Ultra-lightweight design, impact resistance, high-end finish

Smartwatch casings, bicycle frames, power tool housings 

Precision Die Casting for Aerospace and Aviation

The aerospace and aviation industries depend on die casting for advanced parts and components. Die casting creates state-of-the-art parts that can withstand the extreme temperature changes found in these fields. 

At Frigate, expertise in precision machining adapts to high-quality, cost-effective die casting for aerospace and aviation. Skilled professionals ensure your parts and components meet exact project specifications, delivering the precision you need. 

 

Industries We Serve

What You Gain with Us

We make your profitability and operations easier with practical approach.

aluminum casting services
aluminum casting services

↓ 7-8%

OPS COST

aluminum casting services

↓ 2-3%

COGM

aluminum casting services

3X

Aggregation

aluminum casting services

↑ 25%

Machinery Utilisation

aluminum casting services

↓ 50%

Expedition

aluminum casting services

↑ 30%

Frigater Revenue

Superior Dimensional Accuracy with Aluminum Casting

Aluminum casting services offers superior dimensional accuracy, a key benefit for customers. This process ensures precise control over the dimensions of complex parts. With tight tolerances, you get components that meet exact specifications, reducing the need for extra machining. This accuracy leads to better fitting parts, fewer defects, and reliable machine and equipment performance. Enjoy high-quality, consistent results with aluminum casting, making your production process more efficient and cost-effective. 

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does aluminum casting ensure precise dimensional accuracy?

Aluminum casting uses molds that are custom-designed to exact specifications. The process involves pouring molten aluminum into these molds, ensuring the metal fills every corner. Cooling is carefully controlled to prevent shrinkage or warping. This tight control results in components that meet strict tolerances, often within microns, making aluminum casting ideal for parts requiring high precision. 

What makes aluminum casting suitable for complex shapes and thin-walled components?

Aluminum's low melting point allows it to flow easily into molds, making it ideal for casting intricate designs and thin-walled parts. When molten, the material's high fluidity means it can fill detailed mold cavities and narrow sections without leaving voids or defects, making aluminum casting a popular choice for lightweight and complex geometries. 

How does heat treatment affect the mechanical properties of cast aluminum?

Heat treatment, like T6 tempering, is often applied to cast aluminum to enhance its strength and durability. The process involves heating the cast part to a high temperature, followed by rapid cooling and aging. This improves the hardness, tensile strength, and fatigue resistance, making the aluminum suitable for structural or load-bearing applications. 

What role does mold material play in the quality of aluminum castings?

The mold material used in aluminum casting significantly affects the surface finish and dimensional stability. Permanent molds made from steel or iron provide better durability and can handle higher casting volumes. Sand molds, however, are ideal for prototypes or small batches but may produce a rougher surface. Choosing the right mold material helps ensure optimal results based on production needs. 

How is porosity controlled during the aluminum casting process?

Porosity, or tiny air pockets within the metal, is common in aluminum casting. Techniques such as vacuum casting, degassing, or using ceramic filters can be applied to control porosity. These methods remove trapped gases or impurities from the molten aluminum before casting, ensuring the final component has a solid, defect-free structure and improved mechanical properties. 

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