ZL101 102 T6 Cast Aluminium Parts Aluminum Permanent Mould Casting Process
Product Description and Process
Aluminum Permanent Mould Casting Process ZL101 102 T6 Treatment Aluminum Castings 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 CASTING METALS
Aluminum castings are lightweight and able to withstand the highest operating temperatures of all die cast alloys.
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.
A380 Aluminum Alloy
The most popular alloy for aluminum die casting is A380. We use A380 because it has demonstrably the best combination of physical and mechanical properties for casting, including being lightweight, very strong at high temperatures and corrosion resistant. A380 is also very good at retaining dimensional stability even with complex shapes and thin walls and offers high electrical and thermal conductivity.
A383 Aluminum Alloy
Another option for die casters is to use A383 aluminum alloy. This is alloy is typically only used when you are forming intricate components and require very specific die-filling characteristics. While it doesn’t share all the properties of A380, it does offer higher strength at high temperatures with less chance of cracking under heat.
A360 Aluminum Alloy
A360 is harder to cast than A380, which is why many die casters avoid it. However, it does offer higher strength at high temperatures, better ductility and higher corrosion resistance, so you may want to consider this alloy depending on your casting abilities and needs.
A360 vs. A380 v. A383
To summarize the differences between the three types of casting alloys as outlined above, A360 has the best pressure tightness, high-temperature strength and corrosion resistance of the three alloys.
A380 is also highly corrosion-resistant but more cost-effective and easier to work with than A360, so this is the one you would use most commonly if you have budgetary concerns to consider and don’t need the highest levels of corrosion resistance or pressure tightness.
A383 is a modified A380 alloy you would only use if you need precise die filling that you are not getting from your A380 alloy, as it is not as durable as A380.
319 Aluminum Sand Castings
Aluminum alloy 319 is a 6% Si and 3.5% Cu alloy with 1.0 Fe maximum. It has excellent casting and machining characteristics. Corrosion resistance and weldability are very good. Mechanical properties are good in both the heat-treated (T5) and non-heat treated conditions.
The anodized color is generally gray with a brown cast depending on the amount and ratio of silicon and copper.
Typical applications for sand casting 319.0 are a wide variety of structural castings for engine parts, engine crankcases, gas and oil pans, and general commercial applications.
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.|