Cast aluminum is a specific metal that has gone through one of the several processes known as casting. Essentially, it is created when methods such as die casting, mold casting, or sand castingare used to temper the aluminum for use in creating components for many different types of products. This form of aluminum is used for a number of items around the house, as well as machinery and other products that are necessary to the manufacturing of a wide range of goods and services.
 
One of the more common applications of cast aluminum is in the creation of cookware. Just ascast iron is used for skillets, baking pans, and other kitchen essentials, aluminum can also be used for these items. Usually created using the die cast approach, the cookware can withstand the high temperatures required to cook food properly and will remain useful for a number of years with no more than minimal care.This metal is also used to create outdoor furniture, including chairs, gliders, and tables. While not quite as popular as cast iron furniture for the lawn, aluminum patio furniture is somewhat more lightweight and can be moved around the space with greater ease.
 
In addition to cookware and furniture, the cast metal is also used to create a number of motor parts for land vehicles and boats. Components such as connecting rods, pistons, housings, radiator tanks, and other essentials can be created using both die casting and mold casting methods. Even components such as compressors and various types of gears may be created using aluminum of this type.
 
One of the main advantages to using cast aluminum is that the metal is often cost efficient in comparison to other cast metals. The metal also retains a high degree of durability. While it is not necessarily true that it will last as long as cast iron in some applications, aluminum products do tend to hold up well for a number of years. The combination of lower cost and reliable durability makes the metal an excellent choice for many components and products used in domestic and commercial applications.
 
Aluminum Casting
The process of casting aluminum
Casting is the original and most widely used method of forming aluminum into products. Technical advances have been made, but the principle 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
The die casting process forces molten aluminum into a steel die (mold) under pressure. This manufacturing technique is normally used for high-volume production. Precisely formed aluminum parts requiring a minimum of machining and finishing can be produced through this casting method.
 
Permanent mold casting
Permanent mold casting involves molds and cores of steel or other metal. Molten aluminum is usually poured into the mold, although a vacuum is sometimes applied. Permanent mold castings can be made stronger than either die or sand castings. Semi-permanent mold casting techniques are used when permanent cores would be impossible to remove from the finished part.
 
Sand casting
The most versatile method for producing aluminum products is sand casting. The process starts with a pattern that is a replica of the finished casting. Virtually any pattern can be pressed into a fine sand mixture to form the mold into which the aluminum is poured. The pattern is slightly larger than the part to be made, to allow for aluminum shrinkage during solidification and cooling. As compared to die and permanent mold casting, sand casting is slow process but usually more economical for small quantities, intricate designs or when a very large casting is required.
 
Casting Applications
Widespread use in the automotive industry and homes
The automotive industry is the largest market for aluminum casting. Cast products make up more than half of the aluminum used in cars. Cast aluminum transmission housings and pistons have been commonly used in cars and trucks since the early 1900s. Parts of small appliances, hand tools, lawnmowers and other machinery are produced from thousands of different unique aluminum casting shapes. The casting product most often used by consumers is cookware, the first aluminum product that was made available for everyday use.
 
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