Difference Between Cast Aluminum Vs. Die Cast

The best part about the metal fabrication and manufacturing industry is that hundreds of resources and alternatives are available for each requirement. In addition, there are methods available for specific components and shapes, from die casting, injection molding, sand casting, extrusion, etc.

While this makes things better for the quality, sometimes you could get confused between them. One such comparison is between cast aluminum and die-cast when determining the proper method for manufacturing. Let us understand the difference between cast aluminum and die-cast in detail.

CAST ALUMINUM VS. DIE CAST

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Difference Between Cast Aluminium & Die Cast

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While cast aluminum involves aluminum components designed with a casting process done with molten aluminum, die cast is a casting method involving high-pressure die casting with raw materials. The significant difference between the two is the material for casting the products.

CAST ALUMINUM

To cast aluminum in different components, die casting is done by melting it and pouring it into the mold. The metal then solidifies and gets the desired shape. This is what cast aluminum is all about. At the same time, the process itself is called die casting.

TYPES   

While the process is quite similar for both cast aluminum and die-cast, the methods of both are different. Die-cast includes methods like sand casting, gravity casting, low-pressure casting, and other casting processes. All these casting methods involve various molds and metals like copper, aluminum, iron, and magnesium. In contrast, cast aluminum is nothing but a casting method made with only aluminum metal to cast aluminum products.

However, the cast aluminum is done with different heat treatments. T6 is the most common heat treatment. On the other hand, T6 is not suitable for die casting due to a large amount of gas distributed inside the chamber. 

CAST ALUMINUM ADVANTAGES

• With a rigid body and structure, cast aluminum is better in strength and lightweight to create thousands of components.
• From small devices to big trucks, it provides heat resistance and strength.
• Famous for home appliances, patio furniture, and cookware.
• Aluminum being affordable makes the entire process cost-effective and long-lasting, with many features that aluminum brings.
• Great for electronics due to performing in fluctuating temperatures and thermal conductivity.

DIE CAST ADVANTAGES

• Die-cast is ideal for mass production and complex shape designs.
• Die casting creates parts and components that are more durable, aesthetically appealing, and dimensionally stable than other methods.
• It can be done with thinner walls than other casting methods, and the produced parts are much stronger than other methods.
• You can produce thousands of identical parts within specified tolerances before additional procedures and tooling.
• Die casting is an effective option with various molds and materials compatible with the process.

CONCLUSION

Each process comes with its advantages and drawbacks. However, die casting is the most preferred due to its ability for mass production and the various options available. On the other hand, the aluminum cast is ideal for aluminum parts and components.

There are plenty of casting services available in today’s market. Two of the more basic and popular are die casting and sand casting. Below we dive into what each type of casting involves, as well as the benefits and costs of each. This will be helpful to determine which type of casting best suits your next project.

What is Die Casting?

The die casting process consists of red hot liquid metal forced into a die under extreme pressure. In this scenario, the “die” is simply the steel mold which is created to shape the actual product that is being manufactured. Once the liquid metal is poured and injected into the mold, it solidifies, and then is removed from the mold. As soon as the liquid metal cools down, the gating material which is used as a protection source for the liquid metal, is removed and the product is finished. The steel mold is then closed and is immediately ready for your next casting project. This entire cycle is lightning fast, and lasts anywhere between thirty seconds and one minute.

What is Sand Casting?

The sand casting process consists of molten metal poured typically from a ladle into a sand mold. Unlike with die casting, no high pressure is necessary for this process. The sand mold is created when a matchplate, or a pattern made out of wood or plastic, is placed into an enclosure. Sand is then distributed around the matchplate and inside the enclosure. Once the sand is packed in, the matchplate is then removed and the cavity is inserted with molten metal. The metal then solidifies, the mold is opened and the sand is dusted off the hot casing, and the casting is complete. Unlike die casting, the mold needs around five minutes of down and prep time, before it can be reused again.

Die Casting vs Sand Casting

The biggest and most obvious difference between the die and sand casting process is the materials used to form the molds. As we reviewed above, die casting uses a metal mold, while sand casting uses a mold made out of sand. Below we point out the benefits of each process, as well as which applications each are used for.

Die Casting Advantages

• High speed production
• Aids in simplified assembly

Sand Casting Advantages

• Low tooling cost
• More flexibility with size, shapes and weights
• Alloy friendly – can be used with almost any type

Both forms of casting are widely used across multiple industries today. Each type helps accomplish a final production goal. A job that requires precision and complex shapes, like medical device manufacturing, would be best suited for die casting. Any high volume job would fall under the die casting category, based on the quick turnaround time this process offers. For a job that requires a strict budget that will be producing larger pieces and parts, such as a furniture maker, sand casting would be ideal.

Wondering which type of casting might be best for your application? Contact us at Patriot Foundry today!