Aluminum is amongst those metals which can be cast by
every process used in metal Aluminum pet film casting. These processes, in descending order of
quantity of aluminum casting are: die
casting, permanent mold casting, sand casting, plaster casting, investment
casting, and continuous casting. The casting process is selected on the basis
of factors such as cost, feasibility, quality, etc.
Feasibility is not a problem, as all the above methods are
quite practicable. However, the most suitable casting method can be Aluminum polyester film decided
according to the design features or dimensions.
For instance-Large products are made using sand casting. The quality
factor is also important in selecting the casting process. Quality refers to
both, mechanical properties (ductility and strength) and soundness (surface
imperfections, cracking, and porosity freedom).
The methods most commonly used can be described as follows:
Die Casting: As
per the statistics, around 2.5m worth of die-castings of aluminum alloys are produced in the US alone every
year. The process of die casting utilizes almost two times the tonnage of
aluminum alloys as the combination of
other casting processes. Die casting is best suited for large quantity
production of relatively tiny parts. Aluminum die castings upto 50 Kg of weight
can be produced if casting-machine costs and high tooling are justified.
Some common applications of die cast aluminum alloys are inclusive of alloy 380.0 for
Lawnmower housings, Alloy A380.0 for streetlamps housings, dental equipment,
typewriter frames, Alloy 360.0 for frying skillets, instrument cases, cover
plates, parts needing corrosion resistance, Alloy 413.0 for outboard parts of
motor like connecting rods, pistons, housing, and Alloy 518.1 for conveyor components,
escalator parts, aircraft, marine hardware.
Die castings cannot be easily heated or welded due to
entrapped gases. Efforts are being on the war footing to overcome this
obstacle. The die castings of aluminum
alloys are generally produced using aluminum -silicon-copper alloys.
This alloy family gives an excellent combination of corrosion resistance,
strength, and cost, along with respite from hot shortness and high fluidity
which are mandatory for easy casting. If one desires a better resistance to
corrosion, he should make use of alloys having a lower copper content.
Permanent Mold
casting: Permanent mold casting is best suited for high-volume
production. Their size is larger than die castings. These castings have a
very low pouring rate. They are gravity-fed. Outstanding mechanical properties
are exhibited by permanent mold castings. There is a lot of scope for further
improvement if they are given heat treatment.
Some of the most common alloys of aluminum permanent mold casting include Alloy 366.0
for automotive pistons, Alloys 355.0, A357.0, C355.0 for impellers, timing gears, compressors,
missile and aircraft components, Alloys A356.0, 356.0 for aircraft wheels,
parts of machine tools, pump parts, valve bodies, marine hardware, and 296.0,
333.0, 319.0.
Sand casting: This
type of casting involves formation of casting mold (with sand). It is inclusive
of conservative sand casting & lost-foam casting. The first one involves
forming a pattern of sand, pouring the molten metal into it and breaking it
once the product is formed. Lost-foam pattern involves putting a dispensable
pattern of polystyrene in the mold. The rest of the procedure is the same as
conservative sand casting.
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