Aluminum Permanent Mold Castings
Aluminum permanent mold castings are made by gravity pouring molten aluminum alloy into a permanent metal mold. The metal flows into the mold under its own weight, without pressure, and rapid solidification in the metal mold produces a fine structure, accurate dimensions and a smooth surface.
Permanent mold casting is usually chosen when the series is too large for sand molds, but too small – or the part too massive or requiring heat treatment – for high-pressure die casting.
Permanent Mold Casting Parameters at Our Foundry
| Casting weight | from 0.1 to 50 kg |
|---|---|
| Permanent mold machine size | up to 1400 × 1200 × 750 mm |
| Permanent mold machine operation | automatic cycle |
| Alloys | most often EN AC-42000 (AlSi7Mg) and EN AC-51300 (AlMg5) |
| Post-casting processing | CNC machining, grinding, powder coating, heat treatment on request |
Permanent Mold, Sand or High-Pressure Die Casting – Comparison
| Feature | Sand castings | Permanent mold castings | High-pressure die casting |
|---|---|---|---|
| economical series size | prototypes, small and medium | medium and large | large and very large |
| tooling cost | low | medium | high |
| accuracy and surface finish | basic | good | highest |
| wall thickness | thicker | medium | thinnest |
| T6 heat treatment | yes | yes | usually not |
We describe the advantages and limitations of this method in detail in the article permanent mold casting – advantages and disadvantages, and the comparison with high-pressure die casting in the article permanent mold or high-pressure die casting.
Where aluminum permanent mold castings are used
Permanent mold castings go into automotive, agricultural machinery and furniture applications, as well as general machine building: housings, enclosures, covers, brackets and load-bearing components. After heat treatment, EN AC-42000 alloy suits parts requiring higher strength, while EN AC-51300 is the choice where corrosion resistance and surface appearance matter.
How to design a part for permanent mold casting
- provide draft angles on walls so the casting releases easily from the mold,
- avoid abrupt changes in wall thickness, which promote shrinkage porosity,
- round off corners – sharp edges hinder mold filling and weaken the casting,
- plan undercuts and complex bores using cores – metal or sand,
- leave machining allowances only on surfaces that will be machined.
In short: aluminum permanent mold castings are gravity-cast in a durable metal mold – more accurate than sand castings and with lower tooling costs than high-pressure die castings. We cast them in weights from 0.1 to 50 kg, most often in EN AC-42000 and EN AC-51300 alloys.
See also: permanent mold casting – our offer, permanent mold casting – process and variants, casting molds i aluminum casting alloys.
Need aluminum permanent mold castings? Send a drawing or 3D model to odlewnia@adjatech.pl or call: +48 61 662 43 37 (Mon–Fri 8:30 a.m.–4:30 p.m.).
Scope of services: foundry production capabilities.