Custom Cast Aluminium Parts Sand Casting Aluminum Casting Foundry ASTM A356
Product Description and Process
Aluminum Sand Casting Products ASTM A356 Custom Aluminum Casting Foundry
Production process: green sand casting process, pre-coated sand casting process
Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.
Surface treatment process: anodic oxidation, Dacromet coating, powder coating, etc.
Product Material and Uses
Normally produce with ZL101, ZL101A, ZL102, ZL104, ZL106, ZL107, ZL109, ASTM A356 T6, A319, A413, LM6, LM20, LM25, etc.
The aluminum casting products are widely used for electronic industry, auto-car parts, railway parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.
Aluminum Sand Casting Foundry
We have over 20 years of experience in the design and manufacturing of quality aluminum sand castings.
Sand mold casting is the most direct and low cost means of converting metal into a desired shape. Aluminum castings are virtually unlimited in their ability to provide users with a wide range of advantages and applications.
Aluminum has a high strength-to-weight ratio that is approximately one third the weights of cast iron, steel, brass and zinc.
With excellent corrosion resistance, reduced machining cycles, and the ability to anodize, buff, electroplate and powder coat, aluminum castings make it more cost effective than a welded component, stamping or forging.
The light weight of aluminum, the improved strength that engineered alloys offer, and the increased ability of the sand casting process to produce stronger and thinner walled parts allow us to produce a variety of castings for our customers ranging in size from 1 ounce up to 600 pounds.
In sand casting, re-usable, permanent patterns are used to make the sand moulds. The preparation and the bonding of this sand mould are the critical step and very often are the rate-controlling step of this process. Two main routes are used for bonding the sand moulds:
• The "green sand" consists of mixtures of sand, clay and moisture.
• The "dry sand" consists of sand and synthetic binders cured thermally or chemically.
The sand cores used for forming the inside shape of hollow parts of the casting are made using dry sand components.
This versatile technique is generally used for high-volume production.
Normally, such moulds are filled by pouring the melted metal in the filling system. Mould designing is a particularly complex art and is based on the same principle as gravity die casting.
In the "low pressure" sand casting technique, the melted metal is forced to enter the mould by low pressure difference. This more complicated process allows the production of cast products with thinner wall thickness.
Aluminum Alloy Characteristics:
High operating temperatures
Outstanding corrosion resistance
Very good strength and hardness
Good stiffness and strength-to-weight ratio
Excellent EMI and RFI shielding properties
Excellent thermal conductivity
High electrical conductivity
Good finishing characteristics
Aluminum’s strength, corrosion resistance, and heat dissipating properties offer mechanical designers significant advantages. And our proprietary Thin Wall Aluminum Technology has made aluminum die casting an option for even more applications.
535 Almag/Almag 35 Aluminum Sand Castings
Aluminum alloy 535.0, also called almag 35, is an aluminum magnesium alloy that does not require heat treatment to reach full properties. It has excellent corrosion resistance and machining characteristics. Milling and turning speeds are 4X faster than alloy 319.0, and 16 to 18 times faster than gray iron or malleable iron.
The anodizing rating is excellent and the color is satin white after anodizing.
The polishing rating is also excellent and the castings can be buffed to a silvery white color.
The weldability rating is poor and it also is not recommended for leak tight or pressure type applications.
Typically used for parts where dimensional stability and shock resistance is important. It is also used for marine hardware, ornamental fittings and castings where lighter weight and high strength is a prime consideration. Almag 35 is 10% lighter than average cast aluminum alloys, 64% lighter than gray iron and 69% lighter than bronze.
ASTM A/356 Aluminum Sand Castings
Aluminum alloy A356.0 and 356.0 are a 7% Si, 0.3% Mg alloy with 0.2 Fe (max) and 0.10 Zn (max). The alloys have very good casting and machining characteristics. Typically they are used in the heat-treated condition of T5 and T6 hardness properties.
Corrosion resistance is excellent and it has very good weldability characteristics. Mechanical properties are rated excellent particularly if given a solution and aging treatment (T5, T6). The anodized appearance is gray in color.
Typically this alloy is used in castings for aircraft parts, pump housings, impellers, high velocity blowers and structural castings where high strength is required. It can also be used as a substitute for aluminum alloy 6061.
The fact that 356.0 and A356.0 have good castability makes it a logical choice for intricate and complex castings where lightweight, pressure tightness and excellent mechanical properties are needed.
The A in front of an alloy designation denotes a higher purity version of the chemical composition. The differences are in the impurity levels allowed for Fe, Cu, Mn, Cr, Zn, and Ti and are as follows (all maximums):
Typical Mechanical Properties
|Alloy||Temper||Ultimate Tensile (ksi)||Yield Strength (ksi)||Brinell Hardness (500 Kg)||Shearing Strength (ksi)|
|535.0 (Almag 35)||F||40||20||70||27|
|713.0 (Tenzaloy)||F or T5||34||23||75||265|
Chemical Composition (%)
|A356.0||-||7||0.3||-||Fe 0.2 max||Bal.|
|A357.0||-||7||0.6||-||Ti 0.1 Be 0.06||Bal.|
|535.0 (Almag 35)||-||-||6.9||-||Be 0.005||Bal.|
|319.0||Engine crankcases, gas and oil tanks, engine oil pans, engine parts.|
|355.0||Air compressor pistons, printing press, water jackets & crankcases.|
|356.0||Flywheel castings, automotive transmission cases, oil pans, pump bodies.|
|A356.0||High strength airframe and space frame structural parts, machine parts, truck chassis parts, high velocity blowers and impellers.|
|A357.0||High strength aerospace castings.|
|535.0 (Almag 35)||High strength alloy used for electronic equipment, aircraft components and parts requiring a high degree of dimensional stability and strength. Superior ductility makes it an excellent replacement for malleable iron. No heat treat required.|
|713.0 (Tenzaloy)||Automotive parts, trailer parts, pumps & mining equipment.|