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.Â
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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 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.Â
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Our Aluminum Casting Process
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.Â
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.Â
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.Â
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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.Â
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.Â
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.Â
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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.Â
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.Â
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.Â
Copper enhances aluminum alloys' strength, mechanical properties, and heat resistance. Copper-aluminum alloys are used in electrical components, connectors, and high-stress parts applications.Â
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.Â
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.Â
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.Â
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.Â
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.Â
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.Â
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.Â
Certification No. 1234567, ensuring consistent product quality and continuous improvement.Â
Compliance No. RoHS-2024-001, limiting the use of hazardous materials in aluminum castings for electronics.Â
Certification No. AS9100D-456789, ensuring precision castings meet strict aerospace industry standards.Â
Compliance No. FDA-820-987654, ensuring the safety of medical-grade aluminum components.Â
Registration No. REACH-REG-2024-765432, managing the use of chemicals in production.Â
UL No. E123456, for aluminum components used in safety-critical applications.Â
Tolerance for Aluminum Casting Services
Tolerance on key dimensions (length, width, height), ensuring precise fit and function in assemblies.Â
Tolerance on the uniformity of wall thickness, ensuring structural strength and thermal conductivity.Â
Surface roughness tolerance, ensuring the desired finish for aesthetic, sealing, and mechanical purposes.Â
Deviation from a perfect circle, critical for parts requiring rotational accuracy.Â
Deviation from a flat plane, ensuring the part's flat surfaces are ideal for assembly and functional performance.Â
Tolerance on the linearity of features, essential for parts with straight elements and accurate assembly.Â
Tolerance for angular features, ensuring components are cast at the correct angle for correct mating.Â
Precision on the interior dimensions of castings, critical for component fitting and functional integration.Â
Variation in the overall weight of the cast part, allowing for material consistency while managing cost efficiency.Â
Deviation in the positioning of cores, ensuring accurate internal features such as holes and cavities.Â
Maximum allowable porosity in the casting, affecting strength, pressure resistance, and surface integrity.Â
The shrinkage that occurs during the cooling of aluminum, requiring compensation in mold design to maintain dimensional accuracy.Â
Density range of the aluminum alloy, ensuring the material meets strength and weight requirements.Â
Hardness tolerance measured by the Rockwell B scale, important for wear resistance and durability.Â
Tolerance on threaded holes for screw or bolt fitment, ensuring accuracy for fastener installation.Â
Allowable variation in the position of features relative to each other, ensuring correct assembly alignment.Â
The ratio of thickness to diameter, important for parts requiring specific strength and weight properties without warping.Â
Control over the surface texture, ensuring part functionality for seals, friction, and aesthetic purposes.Â
Measurement of a part's ability to withstand shock and impact forces without breaking or deforming.Â
The maximum stress a material can withstand while being stretched or pulled before breaking.Â
The percentage increase in length of a material before it breaks, important for ductility and part flexibility.Â
Quality Testing Standards for Aluminum Casting Services
Provides precise measurement of casting dimensions to ensure compliance with specified tolerances for fit and function.Â
Assesses the roughness of the casting surface using a profilometer, critical for functional and aesthetic purposes.Â
Detects internal porosity and voids within the casting, which may impact its structural integrity and mechanical properties.Â
Measures resistance to deformation, ensuring castings meet hardness requirements for wear-resistance and load-bearing applications.Â
Determines the ultimate tensile strength and yield strength of aluminum castings, ensuring they meet mechanical load requirements.Â
Measures the elongation of a specimen under tensile stress, indicating ductility and material flexibility.Â
Evaluates how well the casting resists sudden impacts or shocks, providing insight into the material's toughness and energy absorption.Â
Analyzes the precise composition of aluminum alloys to ensure they meet material specifications for performance and standards.Â
Analyzes the casting's internal grain structure, ensuring uniformity and proper solidification for desired mechanical properties.Â
Detects shrinkage, surface cracks, and other casting defects that could compromise the mechanical properties or aesthetic appearance.Â
Checks internal cavity precision and integrity to ensure proper functionality in applications requiring high tolerance.Â
Ensures the casting’s weight is within allowable tolerances, important for meeting material requirements and cost efficiency.Â
Identifies leaks and verifies sealing performance for castings used in pressure-sensitive applications like hydraulics or fuel systems.Â
Investigates the casting's microstructure to assess its grain size, phase composition, and distribution, which affects performance.Â
Assesses the casting's resistance to cyclic loading, ensuring it can withstand repeated stress without failure.Â
Measures the ability of the casting material to conduct heat, important for thermal management applications like heat exchangers.Â
Evaluates the aluminum casting's suitability for welding, ensuring there is no loss in material strength or integrity during post-casting operations.Â
Tests the material’s resistance to corrosion in harsh environments, such as marine or industrial applications, ensuring durability over time.Â
Measures the ability of the casting to deform without breaking, critical for parts that need to undergo forming processes post-casting.Â
Analyzes the casting’s grain structure at high resolution to ensure uniformity and optimal mechanical properties.Â
Determines how the casting performs under alternating high and low temperatures, important for applications in variable environments.Â
Ensures the casting adheres to recognized industry standards, including ASTM B26 (Aluminum Alloy Sand Castings) or ISO 9001 for quality management systems.Â
Measures the ability of the casting to resist twisting forces, important for automotive or aerospace applications requiring high torque resistance.Â
Evaluates the casting’s resistance to vibrational stresses, ensuring durability in applications exposed to constant vibration, such as engines or machinery.Â
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.Â
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.Â
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Industries We Serve
What You Get
↓ 7-8%
OPS COST
↓ 2-3%
COGM
3X
Aggregation
↑ 25%
Machinery Utilisation
↓ 50%
Expedition
↑ 30%
Frigater Revenue
Superior Dimensional Accuracy with Aluminum Casting
Aluminum casting 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.Â
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Having Doubts? Our FAQ
Check all our Frequently Asked Question
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.Â
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.Â
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.Â
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.Â
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.Â
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