Is aluminum or cast aluminum better?
The Advantages of Using Cast Aluminum
When it comes to versatility, cast aluminum is tough to beat. This lightweight, attractive metal is a component in thousands of products, from personal hand-held devices to big trucks. Due to its strength, heat resistance, and lightness, it’s also popular in home goods like cookware and patio furniture.
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Cast aluminum is affordable and long-lasting. When it does crack or split, a skilled craftsman or do-it-yourselfer can repair a part by welding cast aluminum, adding to its lifespan.
What is Cast Aluminum?
Cast aluminum is created when aluminum is heated to extremely high temperatures. The molten aluminum is then molded into various shapes and cooled to craft a wide variety of products. Some common aluminum casting molds include:
Die Casting Molds
This high-volume technique allows manufacturers to make products in bulk. Molten aluminum is added to a steel mold or die, then shaped under high pressure.
Sand Casting Molds
The sand casting process offers a high degree of versatility. Though it’s slower than other methods, it’s best suited for small-batch products or those with intricate designs. It also works well for particularly large products.
First, a model of the finished product is created and pressed into sand to create a mold. Molten aluminum is poured into the mold. Once fully cooled, the sand is removed, revealing the final product.
Shell Molds
A type of sand casting, shell molds are created by melding sand into an ultra-thin shell using resin. Shell molds lead to highly accurate results but are a costly process.
Permanent Mold Casting
In this process, aluminum is poured into a mold and solidifies in place. Products made using this technique are typically stronger and more durable than those crafted using die casting or sand casting.
Ceramic Molds
Also known as precision casting due to the detailed work it allows, ceramic molds are crafted from wax or plastic that melts during firing, leaving the mold open for molten aluminum.
Plaster Molds
This technique, a kind of lost casting, uses a plaster mix poured over wax. When the mold heats up, the wax melts and leaves the pattern behind. Aluminum can then be poured into the mold.
Uses for Cast Aluminum
This type of metal has numerous applications in both home and industry.
Common home products made of cast aluminum include cookware and patio furniture. Cookware was the first widespread, daily-use product in the home made from this metal. The metal is also commonly used for components in small appliances, hand-held tools, lawn equipment, and other household machinery.
Cast aluminum accounts for over fifty percent of aluminum used in automobiles, making the auto industry its biggest market. Its lightweight nature helps improve fuel efficiency.
The telecom industry uses this metal as well. Its ability to disperse heat makes it ideal for RF filter boxes. Aluminum castings offer resilience and protection to hand-held devices without adding weight.
In electronics, cast aluminum is essential due to its strong performance under high temperatures, making it especially suitable for connectors and housings.
Cast Aluminum vs. Aluminum
When deciding on the right material for a part or component, it can be tough to choose between cast aluminum and aluminum. They may sound the same to those unfamiliar with the materials, but there are key differences.
Cast aluminum products are typically known for being solid, long-lasting, and low-maintenance. They resist weather, rust, and wind well. The malleability of cast aluminum allows for more detailed designs, offering a variety of unique choices.
Products made from regular aluminum are generally cheaper but lower in quality. While aluminum does not get as hot in high temperatures, it doesn’t provide the same strength. Regular aluminum can dent and scratch easily, so products made from it will show wear and tear more quickly.
In addition to its versatility and durability, cast aluminum is also environmentally friendly. Nearly all aluminum casting in the U.S. comes from recycled aluminum. From home to high-tech industry, this cast metal gets the job done.
Common Products Created with Cast Aluminum
You may be surprised to find out that many commercial products you encounter daily use cast aluminum parts and components or are made entirely from cast aluminum.
Car Parts & Components
Due to its strength and light weight, cast aluminum is very popular in producing car parts. For example, safety-critical parts like airbag housings or seat-belt retractor spools are made with diecast aluminum. Steering knuckles, which support the wheel bearing, are also made with this material, helping to reduce the car's overall weight without compromising strength or performance.
Medical Devices
Many medical devices are made from cast aluminum due to its strength and heat resistance. Common medical equipment you may see made from this metal includes parts for various pumps, surgical tools, components for monitors, and even gearboxes for hospital beds.
Firearms
Die casting is popular for producing firearms. While many firearms may have plastic components, a number of parts are created from die-cast metals, such as triggers, trigger guards, and trigger safeties.
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Cast Aluminum Cookware
For decades, cast aluminum cookware has been a vital tool in well-stocked home kitchens. This versatile product is perfectly suited for stovetop cooking and baking. It is dishwasher safe, making cleanup quick and easy. Despite some myths, it is safe to use for cooking and poses no health risks.
If you’re looking for pots and pans made from this material, the good news is they’re widely available. You can find brand-new sets on major retailers' websites. For a more classic style, vintage cast cookware is available on eBay.
Cast Aluminum Patio Furniture
When investing in patio furniture, you want something attractive, durable, and low-maintenance. If you also want outdoor furniture that comes in various styles, finishes, and colors, cast aluminum patio furniture may be ideal for entertaining and relaxing with family and friends.
Work with The Federal Group on Your Next Casting Project
Whether you’re exploring prototyping options for a new product or have an existing product that you’d like to put into production, The Federal Group USA can help you with your next aluminum die casting project. We’ve provided high-quality metal fabrication services to various industries for over 30 years. Contact us today to request a quote for your die-casting project.
Aluminum vs. Cast Aluminum Patio Furniture Material
What is the best material for patio furniture? There is no definitive answer, but when shopping for outdoor furniture, you will find many choices regarding the material used. While wood is a perennial favorite, other materials stand up better to weather conditions. In this section, we compare cast aluminum vs aluminum patio furniture.
What is Aluminum Patio Furniture?
If you are looking for outdoor furniture that will not rust, aluminum is the preferred metal. Aluminum patio furniture refers to an extruded material, created by forcing aluminum through a machine to shape it into the desired form. An advantage of aluminum patio furniture is its stackability, making it easier to move and store during the winter months.
Aluminum Quality Considerations
Several factors impact the quality of aluminum patio furniture. Heavier pieces usually indicate better quality and lower likelihood of being blown over by strong winds. The nature of extruded aluminum means it can dent and bend easily, although some manufacturers add internal support for additional strength.
Take a good look at the finish of the aluminum patio furniture you are considering. The pieces should be welded with a combination of aluminum, zinc, and steel. Powder coating should be smooth and free of bubbles or blotches. Powder-coated aluminum patio furniture is preferred over spray painting, as it offers a more durable finish.
What is Cast Aluminum?
In considering cast aluminum vs aluminum patio furniture, the former is usually a better choice. Cast aluminum is a solid material, and outdoor furniture made from it typically uses a mold. Molten aluminum is poured into a frame where it sets, allowing for more intricate design details. This makes cast aluminum patio furniture more stable and sturdy.
Will cast aluminum rust? The answer is no. Unlike cast iron, cast aluminum patio furniture will not rust, even if it gets and stays wet for an extended period.
Cast Aluminum Quality Considerations
When shopping, be aware that some cast aluminum patio furniture brands use fillers in the material, producing a cheaper product that is less dense and more prone to breakage. Check whether the manufacturer used 3D molds to form the pieces, ensuring that backs of the furniture are not concave and unfinished. Finally, examine the welds which should be well-sanded and smoothed without compromising strength.
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When it comes to cast aluminum vs aluminum patio furniture, there are advantages and disadvantages to both. Your choice depends largely on your specific needs and sense of style.
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