The melted aluminum alloy flows at the rate of 5m/sec to 15m/sect and eventually it pours in the cavity of die. The system is advantageous as it gives a weldable casting having no air. Aluminum auto parts are manufactured by this process, which is durable and dense in structure. Moreover, die cast products are cost effective, if it is fabricated on a large scale.
Aluminum alloy casting has played an important role in the development of different aluminum products. Alloy casting, development and analysis give the physical and mechanical shape of the particular material. Alloy casting has also augmented the capacity of foundries in new commercial and technical uses.
In a modern method, aluminum alloys castings are fabricated in a different ways. These methods are easy and proficient, using commercial casting systems such as green sand, dry sand, composite mould, plaster mould, investment casting permanent mould, gravity casting, low pressure casting and pressure die casting.
Foundry techniques are also improving, so the material constraint is also more or less removed. Similarly process selection is also being less restricted these days.
Melting and metal treatment:
Aluminum and aluminum alloys melting process is not confined to one process, but in various methods. There are many prevalent processes such as coreless and channel induction furnaces, crucible and open-hearth reverberatory furnaces fired by natural gas or fuel oil and electric resistance and others. The nature of furnace charge is dependent on choice of metal casting operations. The furnace charge may be different from high quality ingot or low quality scrap.
After a certain time at temperature, aluminum alloy casting adsorbs hydrogen and consequently hydrogen content is increased.
Oxidation of melt happens with certain time at temperature. With continuous low vapor pressure and high reactivity, temporary elements are displayed in aluminum alloy casting.
With increasing in melting and turbulence, the rate of hydrogen adsorption increases and transient element loss. Hydrogen porosity and entrapped non metallic inclusions is directly depend on casting quality, and thus affect on mechanical properties of aluminum alloys. Aluminum alloy casting and product fabricate by the process is highly useful for its cost effectiveness and lightweight.