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Best-Selling Precision Casting Factory - Aluminium Alloy Casting Engine Spare Parts – RMC Foundry

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Best-Selling Precision Casting Factory - Aluminium Alloy Casting Engine Spare Parts – RMC Foundry Detail:

Steps of Sand Casting Production Process

1. Making Patterns
Resin or aluminum patterns will be necessary for green sand casting process. Without patterns, the production for castings will be impossible. Sometimes, wooden patterns could be used for small quantity production, but for mass production, resin or aluminum patterns will be more suitable.

2. Molding Process
The green sand molding could be made by three methods typically, including manual molding, molding machine and automatic molding equipment. The manual molding is a traditional molding method, but it still exists because of its capability for large castings at lower costs. The molding machine method could save manpower and produce better quality castings, but it can not produce large castings because of its size limitation of sand boxes.

3. Iron Melting and Pouring
Melting could be done by medium frequency electrical induction furnaces, which could keep the quality good and stable comparing to the traditional furnaces.

4. Sand Blasting and Grinding
After the green sand iron castings are taken out from sand molds, they would be transferred into next steps for shot blasting or shot-peening to remove the sands and oxide outside of the casting parts. Then the operators will cut off, clean and grind the gating heads, risers, parting lines and sharp edges.

Further processing such as heat treatment, precision machining and surface treatment would be proceeded if the drawings or end-users require.

Aluminium and its alloys could be cast and poured by high pressure die casting, low pressure die casting, gravity casting, sand casting, investment casting and lost foam casting. Usually, the aluminum alloy castings have less weight but complex structural and better surface.

Cast Aluminium Grade in Different Standards
AISI W-stoff DIN BS SS AFNOR JIS UNI EN ISO
A356 3.2371 G-AlSi7Mg LM25 4244 A-S7G AC4C - 42000 AlSi7Mg
- 3.2373 G-AlSi9Mg - - - - - - -
A360 3.2381 G-AlSi10Mg LM9 4253 A-S10G - - 43100 AlSi10Mg
A413.2 3.2581 G-AlSi12 LM6 4261 A-S12U AC3A - 44100 AlSi12
A413.0 3.2582 GD-AlSi12 - 4247 - - - - -
A413.1 3.2583 G-AlSi12(Cu) LM20 4260 A-S12 - - 47000 AlSi12(Cu)
- 3.3561 G-AlMg5 LM5 4252 A-SU12 AC4A - 51300 ALMg6
- 3.5101 G-MgZn4SE1Zr1 MAG5 - G-Z4TR - - - -
- 3.5103 MgSE3Zn2Zr1 MAG6 - G-TR3Z2 - - - -
- 3.5106 G-MgAg3SE2Zr1 MAG 12 - G-Ag22,5 - - - -
- 3.5812 G-MgAl8Zn1 MAG1 - G-A9 - - - -
- 3.5912 G-MgAl9Zn1 MAG7 - G-A9Z1 - - - -
355.1 - G-AlSi5 LM16 - AS4GU - - 45300 ALSi5Cu1
A380 - G-AlSi8Cu3 LM24 4250 A-S9U3 AC4B - 46500 AlSi9Cu3(Fe)(Zn)
319 - G-AlSi6Cu4 LM21 - A-S5UZ AC2A - 45000 AlSi6Cu4
319.2 - G-AlSi6Cu4 LM22 - A-S5U AC2A - 45400 AlSi5Cu3

What Aluminium Alloy We Cast by Sand Casting Process:
• Cast Aluminium Alloy by China Standard: ZL101, ZL102, ZL104
• Cast Aluminium Alloy by USA Stardard: ASTM A356, ASTM A413, ASTM A360
• Cast Aluminium Alloy by other Starndards: AC3A, AC4A, AC4C, G-AlSi7Mg, G-Al12

Unified Aluminium association Hardness BHN Ultimate tensile strength, MPa Yield Strength, MPa Modulus of elasticity, GPa Fatigue Strength, MPa
A03550 AA355.0 75-105 255 185 70.3 69.0
A03600 AA360.0 75.0 300 170 71.0 138.0
A03800 AA380.0 80.0 317 159 71.0 138.0
A03830 AA383.0 75.0 310 152 / 145.0
A03840 AA384.0 85.0 331 165 / 140.0
A03900 AA390.0 120.0 280 240 81.2 140.0
A04130 AA413.0 80.0 296 145 71.0 130.0
A04430 AA443.0 30-60 145 48.3 71.0 /
A05180 AA518.0 80.0 310 193 69.0 160.0

 

Aluminum Alloy Castings Characteristics:
• The casting performance is similar to that of steel castings, but the relative mechanical properties decrease more significantly as the wall thickness increases
• The wall thickness of castings should not be too large, and other structural features are similar to those of steel castings
• Light weight but complex structural
• The casting costs per kg of aluminium castings are higher than that of iron and steel castings.
• If produced by die casting process, the mold and pattern cost would be much higher than other casting processes. Therefore, die casting aluminium castings would be more suitable for castings of large demanding quantity.

 

Typical Chemical Composition of Investment Casting Aluminium Alloy by North American Specifications
Alloy Grade Specification Al Cu Si Zn Mg Cr Fe Mn Ti Ag Be Ni P
A356-T6 AMS 4218 Bal 0.20 6. 5 – 7. 5 0.10 0.25-0.45 - 0.20 0.10 0.20 - - -
A 357 AMS 4219 Bal 0.20 6. 5 – 7. 5 0.10 0.40-.70 - 0.20 0.10 0.04-0.20 - 0.04-0.07 - -
F 357 AMS 4289 Bal 0.20 6.5-7.5 0.10 0.40-.70 - 0.10 0.10 0.04-0.20 - 0.002 - -
E 357 AMS 4288 Bal - 6.5-7.5 0.10 0.55-0.60 - 0.10 0.10 0.10-0.20 - 0.002 - -
A201 AMS 4229 Bal 4.0-5.0 0.05 - 0.15-0.35 - 0.10 0.20-0.34 0.15-0.35 0.40-1.0 - - -
C355 AMS 4215 Bal 1.0-1.5 4.5-5.5 0.10 0.40-0.60 - 0.20 0.10max 0.20 - - - -
A206 AMS 4235 Bal 4.2-5.0 .05max 0.05max 0.20-0.35 - 0.10ma 0.20-0.50 0.15-0.30 - - 0.5max -
B206 Bal 4.2-5.0 .05max 0.05max 0.15-0.35 - 0.10max 0.20-0.50 0   1   0 - - 0.5max -

Metal and Alloys  Grade for Sand Casting
Sand Casting Equipment at RMC Foundry
China green sand casting company

China Sand Casting Foundry


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