HOKARE Provide Top and Most Professional Casting Service in China

Aside from that, when manufacturing, Hokare uses different types of methods in Aluminum Casting.

One method used by Hokare is aluminum die high pressure casting. This manufacturing process to which the aluminum is being injected with die casting under a high pressure towards a die or steel molds in order to form a product.

This method can form an aluminum parts precisely which only requires minimum finishing and machining. This process is typically used to produce a product such as aluminum thin wall.

Aluminum die low pressure casting is another method performed by Hokare. In this method, aluminum is transferred to metallic tool from a tight furnace via rising tube. This casting method has a temperature for about 750°C. This method used by Hokare are perfect for products such as thick aluminum.

In Aluminum Casting in China, Hokare is a manufacturer who uses gravity aluminum die casting method which involves the use of steel core, molds and other metals.

Products which undergone this type of method is stronger. In this process, aluminum is poured to the molds, though, sometimes vacuum is also used.

Sand casting is another method used by Hokare for Aluminum Casting in China. This method is very versatile in producing different aluminum products. This process begins by a pattern which is the copy of those finished casting. The patterns will be pressed towards the sand mixture in order to form a mold to which the aluminum will be formed.

Hokare is the most reliable Aluminum Casting supplier in China which are perfect decorative element and be utilized in various applications.

With Hokare’s Aluminum Casting in China, aluminum products are durable and rust-free both suitable for indoor and outdoor applications that can withstand any climate.

Hokare is the leading manufacturer of an aluminum casting in China for various industries such as automotive, aerospace, diesel engine parts, marine, power generation and more. Hokare also do special shapes of Aluminum Casting in China for small appliances, lawnmowers, hand tools and also other machinery.

If you are in an industry which needed an aluminum casting product, Hokare is your expert Aluminum Casting manufacturer in China.

For more than 20 years, we continue to offer a one stop solution for all of your aluminum casting part needs along with our excellent CNC services.

Choose Hokare because we have more than 80 well-knowledge workers to assure you quality and delivery. Moreover, our precision aluminum machining parts and CNC Machining service comes in a competitive price. Our Aluminum Casting parts are 100% inspected by our quality control team before shipment.

To guide and assist you, our sales team is 24/7 responsive and provides an efficient after-sales services. Contact us now!   

Aluminum Casting: The Ultimate FAQ Guide

This guide covers everything you need to know about aluminum casting processes, and techniques.

So, if you want to be an expert in aluminum casting processes – here’s all information you’re looking for.

What is Aluminum Casting?

This refers to a mode of metalworking process, which involves pouring heated liquid metal into a mold or form.

It is ejected once it cools, leading to aluminum component with a high degree of precision and reliability.

Also, it uses a variation of aluminum and aluminum alloys as the liquid metal poured in a mold.

It is a simple, affordable, and versatile method of forming aluminum into a variety of products used in different applications.

The casting process results in shaping the products into various forms.

The aluminum castings contain properties, which are similar to aluminum components.

How does Aluminum Casting Work?

It involves heating of aluminum to its liquid state and pouring the molten material into a mold.

This enables it to duplicate the desirable pattern.

It is essential to make the mold with high precision.

The reason is that it influences the quality of the final product directly in terms of shape and surface finish.

However, the precise method for making aluminum casting may vary depending on various aspects.

Molds can be created from a wide range of materials such as tool steel, among others since aluminum has a lower melting point than steel.

The moment the casting process is over, the aluminum castings rapidly forms an exterior layer of aluminum oxide.

The essence is to help in protecting the surface from corrosion.

What are the Types of Aluminum Casting?

They are quite several, and the ideal one depends on the specific final product you want to attain.

Over the years, several technical advances have taken place, but the principle remains the same.

The commonly used methods include the following;

· Die Casting

It is the type, which forces molten aluminum into a steel die mold under intense pressure.

Besides, it is an ideal aluminum casting technique for high-volume production.

It is also suitable for aluminum parts, which require a minimum of machining and finishing.

· Permanent Mold Casting

It is a casting method, which entails molds and cores of steel or any other metal.

In this case, the heated aluminum liquid is poured into the mold, but a vacuum at a time can be applied.

Aluminum castings made through this method are often more durable compared to die or sand castings.

Where permanent castings are challenging to remove from the finished part, you may consider semi-permanent mold casting technique.

· Sand Casting

It is the most versatile casting technique for producing aluminum products.

This technique starts with a pattern, which is a replica of finished casting.

You can use this method to press any pattern into a fine sand mixture to create a mold where aluminum is poured.

The pattern is relatively large compared to the part manufactured. This is to make it possible for aluminum shrinkage during solidification and cooling.

Sand casting is comparatively slow than die or permanent mold casting. However, economical, especially for complex designs, smaller quantities, and when there is a need for large casting.

· Investment Casting

This casting technique majorly uses plaster molds as well as expandable patterns of wax or any other fusible material.

It entails investing plaster slurry around patterns for numerous castings, and the patterns melt out as the plaster bakes.

Investment casting produces precision parts with walls as thin as 0.40-0.75mm.

Nonetheless, it is a suitable technique for producing a large volume of complex design parts, which hardly requires further machining.

In essence, it prominently reduces cases of internal porosity.

However, the slow solidification and porosity tend to make mechanical properties relatively low.

This technique is ideal for production of parts for precision instruments and jewelry, among others.

· Centrifugal Casting

It is also another common method of forcing aluminum into a mold.

This technique uses cast iron, steel baked sand, graphite, and plaster molds and cores.

Metal molds provide rapid chilling, which leads to a level of soundness and mechanical properties similar to or superior to permanent mold castings.

Examples of parts, which are manufactured using centrifugal casting include wheel hubs, printing rolls, and papermaking rolls.

Additionally, aluminum alloys suitable for plaster, permanent mold, or sand casting can be cast centrifugally.

· Plaster Casting

It is a type of aluminum casting method, which uses either permeable or impermeable plaster for the mold.

A slurry plaster is poured around a specific pattern, which is later removed and plaster mold baked before pouring the casting.

Subsequently, high insulating plaster value allows for castings within thin wads to be poured.

Mechanical properties and the quality of plaster casting is dependent on alloy composition as well as foundry technique.

· Shell Mold Casting

In shell mold casting, the molten metal is poured inside a shell of resin-bonded sand to only 10-20mm thick.

It is comparatively thin than massive molds used in sand foundries.

This method surpasses sand ordinary sand casting in surface finish as well as dimensional precision.

It also cools at reasonably higher rates; even so, the equipment and production process is costly.

Why should you Consider Aluminum Casting?

It offers a variety of worthy benefits, which include the following;

Flexible quantities – It is relatively easy to produce a flexible range of pieces within a specific timeframe using this technique.

It is achievable since it entails innovative mold designs as well as balancing of unit and tooling costs.

Less machining – It reduces machining needs and related costs by providing close dimensional control.

It also provides a smooth finish, as well as total repeatability by minimized secondary machining.

Dimensional accuracy and stability – It produces parts, which are dimensionally stable and also stable.

At the same time, it maintains comparatively close tolerance and, again are resistant to heat.

Multiple finishing techniques – It produces parts with smooth or textured surfaces depending on your preference.

It is easy to plate or finish such parts with the least surface preparation.

Speedy production – This metalworking process provides complicated patterns within closer tolerances than many different production processes.

It requires little or no machining, but it can produce thousands of identical castings before a necessity of additional tooling.

High quality finished product – This process produces superior finished products far much better than many metalwork production processes.

High strength and weight – It produces stronger parts than other methods such as injection molding of similar dimensions.

And this is essential because it helps in enhancing durability of the parts.

Versatility – It is available in various methods, which provides multiple options to choose from.

In essence, it helps to choose the specific type of casting, which meets your budget, preference, and other demands.

Affordability – It is relatively cost-effective since there is reduced machining as a result of low tooling and speedy production.

It thus makes it a better option to consider compared to other methods of metalworking processes.

How does Aluminum Casting compare with Aluminum Extrusion?

These two aluminum processing methods compare on the following grounds;

· Process

Casting is a process, which involves pouring of molten aluminum into a mold and allowed to solidify before it’s ejected.

In contrast, extrusion involves forcing of aluminum billets into a die, thus leading to the desired cross-section.

· Cost-effectiveness

Aluminum extrusion is cost-effective and generally competitive when dealing with complicated cross-sections. It is also affordable in low production runs.

Aluminum casting is cost-effective when producing parts, which require excellent dimensional accuracy and in large production runs.

· Production Speed

Extrusion is comparatively fast and can produce products in as little as six weeks.

Casting, on the other hand, is a bit slower and always dependent on the quantity and complexity of the patterns you’re producing.

· Initial Cost

The initial costs for aluminum extrusion are attractive, which implies, it is generally low.

Fees for custom shapes using extrusion are also lower than in casting.

Aluminum casting, in contrast, has a higher introductory coast.

· Surface Finish and Strength

Aluminum extrusion produces shapes, which have an excellent surface finish and naturally stronger in comparison to what aluminum casting produces.

It is possible to get seams and mold imperfections in aluminum casting parts.

And this often calls for a secondary process referred to as fettling as a way of removing such imperfections.

It also produces parts with tighter tolerances than aluminum extrusion.

· Size Restriction

Aluminum extrusion has a size restriction, which is dependent on the billet and cylinder capacity of the extrusion process.

On the other hand, castings have no such limit, and you can use it to produce very large items.

· Aluminum Alloy Melting Point

Aluminum casting is limited to metals alloys, which naturally have low melting points.

On the other hand, aluminum extrusion can use any type of aluminum alloy effectively irrespective of whether it has a low or high melting point.

Which Factors should you Consider when Choosing Method of Aluminum Casting?

It can be difficult to choose a particular type of aluminum casting method for your parts, especially if you are a newbie.

Nonetheless, it is equally important to know which method suits your demands.

Some of the ideal factors you need to look into when choosing the most suitable casting method include the following;

· Production Quantity

You have to make your choice based on the number of aluminum parts you require.

It will make it easy for you to determine the ideal aluminum casting for your particular parts.

· Time and Speed

You have to know how long the casting process takes.

Make your choice based on whether you need the parts immediately or after a particular time.

For instance, die casting can last between 8-12 weeks, of course, depending on production run.

Nevertheless, you need to plan and follow the schedule. You should also allocate adequate time for each project.

· Strength

Every casting process often produces parts with varying elongation, physical properties, and strength.

Aluminum parts are, of course, stronger on their own and the casting process can as well strengthen the parts.

· Thermal Properties of the Required Part

Each casting technique has particular preferred metal allows, which are best suited for every thermal property requirement.

Different aluminum alloys have varied thermal characteristics.

For instance, if you are going to use aluminum and zinc parts, the ideal technique to use would be die casting.

· Surface Finish

You should also identify the ideal type of aluminum casting based on the type of surface finish you require for your parts.

There are methods, which offer smooth texture, whereas others provide a relatively rough texture.

· Cost

It is a great determinant, which you ought to consider when choosing the best aluminum casting method.

For instance, die casting is often regarded as the cheapest option per product.

However, in this case, you also need to consider cost of tooling since the method requires a large number of parts to break even.

In a nutshell, as much as cost is a vital consideration, you also need to find a balance between the tooling and unit costs.

How long does Aluminum Casting Process Take?

It varies based on several aspects. The major determinant, in this case, is the preferred casting method.

Different aluminum casting methods take different duration to produce aluminum parts.

For instance, die casting, which is common in many applications, can take up to about 8-12 weeks.

There are some techniques, which can as well take relatively shorter up to 4 weeks and others longer.

The production quantity is the other aspect, which determines the duration casting process can take.

If you in need of a larger quantity, it is quite obvious it will take a bit longer compared to a smaller quantity.

Moreover, the complexity or simplicity of the part patter is also a determinant element of aluminum casting production.

Complex patterns can take longer since it is challenging to design and produce the same, especially where precision is a concern.

Also, the dimensional accuracy of the aluminum part you are casting determines the speed the process takes.

It may take longer to produce components that are thin and require precise dimensions.

In contrast, parts, which require comparatively thick surfaces may take little time to produce.

Does Cast Aluminum Rust?

Not at all.

Cast aluminum is generally, a non-ferrous metal, which implies it does not contain iron in it.

Moreover, this type of aluminum also has several surface finishing making it difficult to rust

In a nutshell, the casting process aluminum goes through, as well as the general surface finishing prevents any form of rust on its parts.

What is the Cost of Aluminum Casting?

There are numerous factors, which you must account for when determining the cost of aluminum casting.

Therefore, it makes it a bit tricky to state the precise cost of this metalworking process outrightly.

Mostly, the pricing is dependent on the type of casting technique you are using.

Die casting is typically regarded as the most cost-effective casting method for aluminum.

However, you still need to figure out the tooling cost, which can be high since this method requires a lot of it.

Sand casting can range from $500 to $7500, of course, depending on a wide range of prevailing circumstances.

The complexity or simplicity of the aluminum casting part is also another element, which defines the cost of this process.

Parts with simple patterns are generally cheaper to produce than those with complex patterns.

The dimensional and tolerance requirements also affect the pricing model of aluminum casting.

Relatively thin parts with higher precision will be more expensive to produce than larger parts with lower precision.

Also, the production quantity influences the overall cost of aluminum casting.

Typically, it is more cost-effective to have a higher production run compared to a lower production run.

In large production runs, you end up reducing on several expenses such as tooling costs, which allows you to save a significant amount of money.

What Types of Surface Coatings can you Apply on Aluminum Casting?

They are quite numerous, but the most commonly used ones include the following;

Anodizing – It refers to a surface coating method produced by electrolytic passivation techniques.

It increases the thickness of natural oxide layer on the surface parts of aluminum parts.

Other than the natural oxide film, it also provides additional protection to the surface parts.

Plating – It is a type of surface coating, which involves depositing a substance on a conductive surface.

Alocrom – It refers to a two-pack chromate conversion coating, which is applied to aluminum cast parts chemically to provide corrosion protection. It can be applied before painting or powder coating.

It is also essential when protection or electrical conductivity is necessary.

Painting – Also known as powder coating, is a natural coating method, which involves painting or powder coating the pre-treated or non-treated aluminum parts.

It produces attractive parts, which you can customize to meet your demands.

E-coat– It is a method, which uses electrical current to deposit the paint.

This surface coating provides corrosion protection over a longer duration, and it is also more affordable than other painting options.

Casting impregnation – It is a surface coating, which seals micro-porosity in castings, which are required to be pressure tight. It could be an interim solution or assurance.

How accurate is Aluminum Casting?

The precision is dependent on the actual type of aluminum casting method you are using.

Nevertheless, you can cast aluminum of an internal diameter to within +/- 100 microns.

It shows you can achieve high accuracy with aluminum casting.

What are the Best Alloys used in Aluminum Casting?

There are several aluminum alloys you can use in aluminum casting.

Even so, the best alloys for this metalwork process have a low melting point as a way of yielding cost-effective products.

Some of these alloys include; copper, silicon, zinc, manganese, tin, and magnesium, among others.

However, the most prominent aluminum casting alloys are;

• Aluminum: 360, 380, 383, 413 and A304 K-Alloy
• Zinc-Aluminum: ZA-8, ZA-12, and ZA-27

What are the Applications of Aluminum Casting?

Aluminum casting is used in a wide range of applications. Some of the common areas of application include the following;

Automotive industry – It is arguably the largest sector, which utilizes aluminum casting.

Cast products make up more than 50% of aluminum used in automobiles.

Aerospace industry – It is used for manufacturing a wide range of high precision parts for air crafts.

It is particularly essential since this sector does not provide room for any error regarding the designs of the parts.

Power generation – Most parts used in power generation plants are designed from aluminum casting.

They are ideal due to high thermal properties and durability, making it suitable to yield best results in generating power.

Sports industry – Aluminum casting parts are also utilized in a wide range of sporting equipment such as gym instruments, among others.

It is also used for assembling different compartments of motorsports equipment.

Electrical and electronic industries – Different parts of electrical equipment such as enclosures are made using aluminum casting parts.

Construction – It is a no-brainer that aluminum casting parts can as well be used in various aspects in the construction sector.

Is Aluminum Casting Environmentally Friendly?

Yes.

It is one of the leading methods of metalwork processing, which poses no danger to the environment.

It meets the tenets of reducing, reuse, and recycle approach, thus making ecofriendly.

Aluminum casting uses less energy, thus producing a relatively smaller carbon footprint compared to other means of manufacturing.

Secondly, whenever a casting part reaches the end of its lifespan, you do not necessarily need to discard it.

Instead, you can choose to take it to speciality mills for retooling to allow it to accommodate different but larger products.

The aluminum casting materials and sub-materials are recyclable.

You can use several methods to recycle such parts using energy-efficient means.

Its recyclability is also fundamental as far as eliminating the frequency of active mining is concerned.

What Quality Standards must Aluminum Casting Comply with?

There are numerous quality standards certifications, which aluminum casting can comply with.

Some of the commons ones include the following;

ISO9001 – This refers to an international standard stipulating the requirements for a wide range of quality management systems and processes.

It demonstrates ability of a company to produce products, which meet the requirements of the clientele and regulatory bodies.

CE – It refers to an international quality standard approving the product conforms to all the necessary safety, health, and environmental requirements.

It is majorly predominant for products getting to the European Union.

ASTM International – This is an agency responsible for designing and publishing voluntary accord on technical considerations for equipment, services, and systems.

API Q1 & Q2 Certification – This is a universal quality standard stipulating ideal requirements and also offers an endorsement for machining considerations.

These may include materials, functional interchangeability, and technical performance, among others.

PMPA – It is an acronym for Precision Machined Products Association.

It is an international standard agency, which creates and regulates policies in regard to interests of precision machine products.

Why is Core Venting necessary in Aluminum Casting?

It enables the gases trapped and evolved within the mold during aluminum casting process to exit without being forced into liquid metal.

What happens is that air contained or trapped in the mold has to exit.

Otherwise, the melting will compress and also trap the air in the cavity.

Therefore, this function offers sufficient permeability to allow gas in the molding material to escape from the core.

Core venting is primarily vital in aluminum casting process since it enhances production of quality parts.

Are there any Disadvantages of Aluminum Casting?

Yes, quite a number of shortcomings.

However, this is also dependent on the specific aluminum casting method you are using.

Each method has its particular disadvantages, but some of the general ones include the following;

Higher introductory expenses – Founding an aluminum casting plant can be quite expensive investment.

The cost of purchasing the molds, machines, and other types of gears for the process is quite high.

Limited to fluidity – It is only ideal for aluminum and other metals, which may flow upon heating.

For instance, in die casting, it would be practically impossible to a material, which cannot flow through it.

Restricted to higher production – Aluminum casting makes economic sense for large production runs.

Small production runs are expensive; thus, the reason most companies stay clear of modest quantity production.

Requires highly-skilled labor – The process is labor-intensive and thus needs highly qualified personnel to handle.

This may limit production runs or even quality unless you have skilled labor handling it.

What are the Types of Tooling for Aluminum Casting?

They are quite a number and, in most cases, may vary based on the specific casting method you are using.

However, the general tooling for most of the casting methods include the following;

Casting mold – It is used for shaping a product during casting process.

It encompasses steel dies and two hardened tools, which form a cavity if combined.

The casting mold can be more than two, depending on the complexity of the pattern.

Trim dies – It cuts excess aluminum from die-cast parts, and it is mounted on a trim press.

This makes it to hydraulically force two halves of trim die together with the numerous tons of pressure.

Casting tooling inserts – These are steel components, which produce cavities and little extra for accommodating temperature fluctuations of molten aluminum injecting under force.

Unit die tooling – It is relatively large casting tooling inserts but smaller than a finished mold.

It utilizes less steel compared to complete mold but more steel than die casting insert.

Family mold tooling – It is designed to save on cost when casting multiple types of parts.

It consists of a casting mold or with few or several cavity die inserts.

Prototype casting tool inserts – It is more or less similar to the ordinary casting tool insert.

The major difference is a prototype casting tool insert is designed from a lower grade of steel and not necessarily heat treated.

How do you Prevent Aluminum Casting from Defects?

Aluminum casting is prone to various defects, especially if you do not adhere to some of the critical parameters during this metalworking process.

But before figuring out ways of preventing aluminum casting defects, it is necessary to determine such defects and their possible causes.

The common defects and prevention measures of the same in aluminum casting include the following;

· Gas Porosity Defects

It usually occurs when aluminum traps gas, especially during casting, thus forming bubbles upon cooling and solidification of the material.

Examples of gas porosity defects in aluminum casting include pinhole, open hole, and subsurface blowhole, among others.

You can prevent it by increasing permeability of mold and cores by allowing air escape and exit.

You can as well dry out molds before use and store. Moreover, you can increase solidification rate by decreasing aluminum temperature during casting.

· Shrinkage Defects

It appears as a depression in casting occurring during the solidification process.

It is also a common defect, which arises as a result of aluminum being less dense as a liquid than a solid.

Large shrinkage cavities tend to undermine aluminum casting integrity, which may lead to eventual breakage under stress.

Examples of aluminum casting shrinkage defects are open shrinkage and closed shrinkage defects.

An ideal way of preventing it generally involves the enhancement of the casting structure.

This may include designing a running system, which has risers to ensure a continuous flow of molten aluminum.

· Mold Material Casting Defects

These refer to defects related to the mold material mostly common in sand casting.

Examples of these defects include fusion, cuts and washes, swells, run-out, and metal penetration, among others.

A suitable way of addressing such defects is by majorly changing the mold.

Nevertheless, each mold material casting defect may call for a unique prevention measure upon examining the actual cost.

· Metallurgical Casting Defects

They come in two major forms, which include hot tear and hard spots.

The former appears as an irregular crack in a branched pattern.

Some of the cracks are apparent and whereas others require magnification.

An ideal way to prevent hot tear is by modifying the mold as a way of improving collapsibility.

Hard spots, on the other hand, appear as relatively rigid marks than the surrounding area.

It happens because it cools down quicker than the surrounding material.

It is prevented by correcting the cooling practice and possibly changing the chemical composition of the metal.

· Casting Shape Defects

They are the types of defects, which affect the general shape of the final casting.

They usually arise as a result of different causes ranging from carelessness, improper clamping, and different solidification rates of various sections.

Examples of some of these defects include warping, burrs, flash, shift, or mismatch, among others.

The general approach of preventing this is by using an appropriate molding box and closing pins and adding an appropriate ingredient ratio.

You can also ensure you normalize heat treatment to remove residual stress, especially in preventing warping.

Are Aluminum Castings Prone to Porosity?

Not necessarily, but it is a common defect.

It usually arises, especially when certain parameters are not met during casting process.

It occurs as a result of gas formation or solidification shrinkage when aluminum is in a molten state.

The bottom line is porosity is a typical defect in most of the aluminum casting parts depending on the method used and types of ingredients incorporated.

What Type of Parts are Suited for Aluminum Casting?

They are several but some of the common ones you are likely to see around include the following;

• Refrigerator compressor frame
• Cylinder head
• Turbo turbine
• Memorial relief
• Brake master cylinder
• Engine blocks
• Turbine blades
• Oil sump
• Sump guard
• Motorcycle head pipe
• Outboard motor swivel
• Shafts

What is the Lead Time for Aluminum Casting?

It depends on a wide range of factors.

For instance, the specific method of aluminum casting is one of the aspects, which define the exact lead time for this process.

Some methods are relatively fast and tend to take fewer days than other techniques.

The other factor determining the lead time is volume of parts manufactured within the specific period.

Most of the companies offering these services tend to have a restricted MOQ.

In essence, the MOQ is essential since it helps in reducing tooling and general production cost.

Even so, higher volumes may take more time to cast compared to relatively low volumes, irrespective of the method.

The nature of designs also affects the lead time for aluminum casting.

Simple patterns are easy to produce since they do not require much attention or detail.

Complex patterns, on the other hand, requires attention to detail and hence may require much time to produce.

In a nutshell, there is no specific lead time for aluminum casting.

However, it can range between 4-12 weeks, depending on the aforementioned and other prevailing factors.

How do you Control Quality in Aluminum Casting?

Significant attention is provided when it comes to controlling and inspection of productive processes in all phases of production.

We have invested in advanced and innovative machines, which enhance precise checking such as roughness meter and micrometres.

We monitor, test, and analyze each custom aluminum casting cycle to meet your exacting standards.

Our facility complies with all the necessary quality assurance standards, such as ISO9001 and ISO/TS 16949, among others.

At Hokare Machinery, we produce high quality aluminum casting. Contact us today for best prices on aluminum cast parts.