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Metal > Aluminium > Aluminum CastingCastings:Casting is a simple, inexpensive, and versatile way of forming aluminum, so it is not surprising that it was also the first method used. Such historical items as the baby rattle for the French’s emperor’s son, the cap atop the Washington Monument and the tea kettle were all produced by casting. The Production Process:Today, casting continues to be the most widely used method of forming. Technical advances, of course, have been made, but the principlImagee remains the same: molten aluminum is poured into a mold to duplicate a desired pattern. The three most important methods are die casting, permanent mold casting, and sand casting. Die casting, in which molten metal is forced into a steel die, or mold, under pressure is normally used for high-volume production. Accurate parts, requiring a minimum of machinery can be produced. Permanent mold casting involves molds and cores of steel or other metal. Molten aluminum is generally poured into the mold, although vacuum is sometimes applied. Permanent mold castings can be made stronger than either die or sand castings. Semi-permanent mold casting, which uses expendable cores of sand or other material, is used when permanent cores would be impossible to remove from the finished part. The most versatile method is sand casting. Virtually any pattern can be pressed into a fine sand mixture to form a mold into which the aluminum is poured. This is a slow process, but usually more economical for small quantities, intricate designs, or when a very large casting is needed.
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