Die Casting Blog for Cast-Parts Aluminum Die Cast Parts and Zinc Die Cast Parts manufacturing and cast parts production

Pressure Die Casting Aluminum Boxes vs. Sand Casting. Facts should be revealed in the battle entitled, “Pressure Die Casting Aluminum Boxes vs Sand Casting.” This is necessary so that one can determine which of the two methods is more effective. What does pressure die casting has that sand casting does not have?

The pressure die casting method involves the injection of molten aluminum under high pressure and high speed into the die steel die in order to produce aluminum boxes. It is inexpensive but is more effective when it comes to producing thinner walls that can be cast when compared to the walls produced in sand casting. Thousands of aluminum boxes can be made through pressure die casting everyday without compromising the quality and dimensional accuracy of the products. How about sand casting?

Sand casting, on the other hand, is another process which requires the use of sand mixture to mold the molten aluminum. It is cheaper when compared to the other processes used in manufacturing aluminum like die casting. It can also be utilized not just in high temperature metals but also in low temperature ones. Aluminum, just like copper, magnesium, iron, and nickel alloys, belongs to the category of low temperature metals. In the sand casting method, a mold must be created in the sand. Afterwards, a gating system must be put together then the pattern is taken out. In the next step, the molten aluminum is finally poured into the mold cavity. The metal should be allowed to cool down so that it can solidify before the sand mold is broken and the casting is removed. The accuracy of the method depends upon the type of the sand used and the molding process executed.

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Methods for making Die Casting Aluminum Boxes. There are Methods for making Die Casting Aluminum Boxes. Die casting aluminum boxes through a process where molten aluminum is forced under high pressure into mold cavities. This process, invented in the 1830’s by Elisha K. Root, makes sure that the boxes which will be produced have a fine surface quality, well detailed design, and must also be dimensionally stable. What are the methods?

The first method requires the mold to be sprayed with lubricant and then closed. The lubricant is necessary since it can control the die’s temperature and can also aid in casting removal. Between 10-175 Mpa or 1,500-25,000 psi is the pressure necessary before the molten metal is shot into the die. The said pressure is maintained even after the die is filled. The die will only be opened after the casting has solidified. When it is opened, the ejector pins shall eject the shots. Afterwards, the scrap with the gate, flash, sprues, and runners are separated from the castings. A sprue is a passage where the molten aluminum can be introduced into the mold while flash is excess material connected to the product which must be removed. The removal of the scrap, gate, flash, sprues, and runners can be done through the use of a hydraulic or power press or can even be done by sawing. However, sawing requires grinding in order to even the scrap marks.

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