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When it comes to versatility, cast aluminum is hard to beat. This lightweight, aesthetically pleasing metal is an integral part of thousands of products, from personal handheld devices to large trucks. It is also popular in household items such as cookware or patio furniture due to its strength, heat resistance and lightness.

Cast aluminum is affordable and durable. When it does crack or split, a talented craftsman or do-it-yourselfer can extend the life of the part by welding cast aluminum to repair the part.

What is cast aluminum?

Cast aluminum is created when aluminum is heated to extremely high temperatures. The molten aluminum is then molded and cooled to create a variety of products. Some common aluminum casting molds include.

Die casting mold

It is a high-volume technology that allows manufacturers to mass-produce products. Molten aluminum is added to a steel mold or die and shaped under high pressure.

Sand casting mold

The sand casting process is highly versatile. While it is slower than other methods, it is best suited for low-volume products or products with complex designs. It is also suitable for particularly large products.

The first step is to create the finished model. Press the model into the sand to make the mold. The molten aluminum is poured into the mold. Once completely cooled, the sand can be removed and brushed off to reveal the final product.

shell mold

A type of sand casting, shell molds are made by using resin to melt sand into an ultra-thin shell. Shell molding yields highly accurate results, but is an expensive process.

permanent mold casting

During this process, aluminum is poured into molds and solidified in place. Products made using permanent pattern casting techniques are generally stronger and more durable than those made using die casting or sand casting.

ceramic mold

Also known as investment casting because it allows detailed work to be done, ceramic molds are made using the investment casting technique. Ceramic molds are made of wax or plastic that melts or disappears during firing, allowing the mold to open for the molten aluminum.

plaster mold

This technique is a lost mold that uses a plaster mix poured over wax. When the mold is heated, the wax melts and leaves the pattern. The aluminum can then be poured into the mold.

Cast aluminum use

This metal has a wide variety of uses in the home and industry.

The two most common cast aluminum home products are cookware and patio furniture. In fact, cookware was the first everyday household item to be made from this metal. The metal is also commonly used in components of small appliances, hand tools, lawn equipment and other household machinery.

Cast aluminum accounts for more than 50 percent of the aluminum used in cars, and the industry is the largest market for the metal. It has also been widely used in motor vehicles for over 100 years. Its lightweight properties help improve fuel efficiency.

The telecommunications industry also uses the metal. Its ability to dissipate heat makes it an ideal material for RF filter boxes. Aluminum castings also provide resilience and protection to handheld devices without adding weight.

Cast aluminum is critical to electronics. Its strong properties at high temperatures make this metal especially suitable for connectors and housings.

Cast aluminum and cast iron

Like cast aluminum, cast iron is used in many similar applications. However, there are some major differences between the two.

Cast aluminum has many advantages. First, it is much lighter than cast iron. Cast aluminum doesn't rust easily, whereas cast iron can rust quickly if you don't take care of cleaning and storage. Cast aluminum cookware is also generally less expensive than cast iron.

One of the great advantages of cast aluminum over cast iron is that it heats up and cools down faster than iron. This is a very attractive feature in the production of a wide range of products such as cast aluminum cookware. Aluminum is also generally easier to maintain than cast iron. This is especially important for those intending to produce consumer goods.

For many consumers, choosing cast aluminum or cast iron is a personal preference. However, when you actually produce your product, it's important to research both options to see which is best for your particular application.

Whether you are exploring prototyping options for a new product, or you have an existing product that you want to bring into production, JC Casting can help you with your next aluminum die casting project.