When manufacturers melt ingots of aluminum and its alloys and then pour it into a mold to give a particular product shape, this is cast aluminum. Casting aluminum products are made by different types of casting processes such as sand casting, die casting, permanent mold casting, etc.
On the other hand, when hot billets of aluminum and its alloys are pushed through a die in order to make a particular cross-section this is extruded aluminum. Extruded aluminum products can be made by different types of extrusion processes such as cold extrusion, hot extrusion, friction extrusion, micro extrusion, etc.
The manufacturing process is not the only difference between cast aluminum and extruded aluminum. More differences are shown in the cast aluminum vs extruded aluminum table below:
Key Points Cast Aluminum Extruded Aluminum Product Size The size of products is not dependent on the size of ingots The size is limited to the size of the billet of extruded aluminum. Product’s Shape Cast aluminum products have more complex shapes than extruded aluminum. Extruded aluminum products are simpler than cast aluminum products. Surface Finish Products have a rough surface finish after casting. Products have a smoother surface finish after extrusion. Strength of Part Products are subjected to more defects and have less strength than extruded aluminum. Extruded aluminum products have fewer defects and more strength. Die Properties Casting dies are costlier and do not last as long as extrusion dies. Extrusion dies are cheaper and last longer. Cost of Production Short volume production costs more but large volume production costs less. Short volume production costs less but large volume production costs more. Time of Production Takes more time than extrusion to produce a part. Takes less time than casting to produce a part.
If you are looking for the best die casting aluminum manufacturer in China, contact Sunrise Metal. In Sunrise Metal, we have the most advanced and modern technology for die-casting aluminum alloys. We also offer additional casting services like machining and finishing of the products.
Aside from aluminum alloys Sunrise Metal also provides services for zinc alloys. However, we mostly work with A360, A383, A380, ZA8, ZA12, ZA27, Zamak Alloys, and some other aluminum die casting alloys.
Our die casting service includes vacuum die casting, pressure die casting, hot chamber, and cold chamber die casting. For cast aluminum alloys, we use cold chamber die casting but for zinc alloys, we use hot chamber casting.
Different aluminum alloys serve different purposes because they have different mechanical properties. Some alloys are comparatively lighter in weight while others are stronger and more durable. As aluminum extrusion is one of many aluminum parts manufacturing processes, some particular alloys are suitable for extrusion. For example:
These aluminum alloys are non-heat treatable but they have good corrosion resistivity and thermal conductivity. The 3003/3103 alloys have better weldability than 1050 alloys.
This aluminum alloy is easier to weld than 6000 series aluminum alloys. It is also high corrosion resistive against saltwater and therefore this alloy is most suitable in the marine industries.
6000 series aluminum alloys are the most suitable alloys for extrusion. There are different alloys in this series such as 6005, 6061, 6063, 6463, and more. However, 6005 alloys have higher durability and strength than others.
The 6063 alloy is popular for having a better surface finish and it also heat-treatable. The 6463 Alloy is quite similar to the 6063 alloys but it is mostly used for architectural purposes, unlike the 6063 alloys.
Below are the aluminum alloys which are most suitable for casting:
Both these aluminum alloys are lightweight and quite strong at a higher temperature. They are extremely stable, corrosion-resistant, which have good thermal conductivity, and also suitable for complex parts. But A383 is less durable than A380.
This aluminum alloy has better ductility and corrosion resistivity than the previous two alloys. The A360 alloy is also suitable for making complex components. But this one is a pressure casting aluminum alloy and is harder to cast than the A380 and A383 alloys.
These are zinc-aluminum alloys and the number in the name indicates the percentage of aluminum in the alloy. Higher aluminum makes a higher melting point and higher density for the alloys. ZA8 is suitable for hot chamber casting but ZA12 is for cold chamber casting.
Both cast aluminum and extruded aluminum have advantages and disadvantages over each other. But manufacturers can make some components by only using the casting process and vice versa.
So which one you choose will depend on the part that you need. For example, if you want to produce door or window frames, handrails, irrigational pipes, seamless tubes, then extrusion is better. Because these are simple structures and are easier to extrude rather than casting. This will also save production costs.
On the other hand, if you want to produce complex parts like engine components, air valves, chassis, clutch bracket, etc. then casting is the best choice. These complex parts are not possible to produce with the extrusion process.