Introduction

If your choice of metal for your product is aluminum, then you’re most likely looking into cast vs extruded aluminum. Aluminum like other metals go through various manufacturing processes such as casting and extrusion before they are used to get the desired product. 
These different forming methods contribute to the overall quality of your finished product, hence the need to understand the processes involved, how it works, as well as their advantages and disadvantages. Having this information will help you avoid questions like “what does extruded aluminum mean”, and understand the differences between cast vs extruded aluminum. This article will help you understand all this, and also inform you on how to get the best aluminum die casting service in Raidy Mold.

What Is Cast Aluminum

Aluminum casting is a manufacturing process that involves melting of aluminum metal into molten form, and pouring the molten metal under high pressure into a mold. When it cools and solidifies, it takes the shape of the mold. While there are various casting methods such as sand casting, high pressure casting, plastering casting, etc., they usually all involve the same basic process, of melting metals to molten form and pouring into steel mold cavities.

This casting method is utilized in industries such as automotive industry, cookwares, electric components, etc., that require bulk production of the same products. When the molten metal solidifies inside the two part mold, the mold is opened to remove the item. The mold cast being reusable allows for the process to be repeated over and over again.

Advantages of Aluminum Casting

The advantages of aluminum casting are endless, making it one of the most commonly used manufacturing processes up till date. Some of those advantages include;

• Easily produce complex shapes

The first advantage of the aluminium casting is its to produce complex shapes in various sizes easily. The mold cavity is usually manipulated into making both simple and complex designs as seen in the automotive industry, ensuring to achieve the high tolerance the finished products require. 

• Suitable for Products of Various Sizes

This type of processing method is known for being used for large and smaller-size products. Without any size limitations, it makes the industries in which this method can be applied versatile, and are commonly used in making large engine parts like propellers..

• Versatility of Material Choices

The aluminum casting process can be used on different alloys of aluminum easily. This option of versatility allows for it to be able to meet specific needs during production such as strength, thermal properties, etc.

Disadvantages of Aluminium Casting

Aluminum casing method is an efficient manufacturing process, however has some drawbacks. These disadvantages include; 

• Capital Intensive 

An aluminum casting initial set up is quite expensive due to complex machinery and materials that are required. The process of aluminum casting also tends towards high scrap rate during production hence further increasing cost implication of the entire process. 

• Prone to Porosity

The casting manufacturing process is more prone to porosity when compared to other processes. These tiny air bubbles that find their way into the cast become holes in the finished product which in turn reduces the quality and strength of the finished products. 

• Extra Machining is Required

Using the aluminum casting has an added disadvantage as there is need for extra machining such as filing and smoothing of the finished product. This takes up extra time, energy, as well as resources.

What Is Extruded Aluminum

Extrusion is another form of manufacturing process you must have heard about as it is commonly used in the manufacturing industry. If you’ve ever asked the question what extruded aluminum is, then this section will tell you all about it. The extrusion method isn’t as complicated as other manufacturing processes. This is simply done by forcing out the aluminum alloy material through a die after which it comes out the end in a cross-sectional shape.

The extrusion process begins with heating blocks of aluminum to a temperature that keeps it malleable but not enough to melt it. After heating, the aluminum is loaded into the extrusion press, which applies pressure to the heated aluminum forcing it out in long bars. These long bars are made to cool in order to maintain their shape. Water cooling, they can be cut, and any additional machining required can now be carried out.

Advantages of Extruded Aluminum

The extruded aluminum method is quite effective and has numerous advantages which include;

• Less Start-up Cost

Considering cost implication between extruded aluminum vs cast aluminum, extrusion is the least cost effective. The machinery involved isn’t as capital demanding as other processes, and requires very little machining after the work is done. 

• Quality Finished Products

If you’re working on products where the strength of the material is very important, aluminum extrusion is the better choice as the finished products obtained are stronger.  The process of extrusion is also one that ensures there is no entrapment of gasses, producing pore free, tough, and fine surface finish of products.

• Dimensional Accuracy

While the extrusion process doesn’t allow for more complex designs, it provides a high level of dimensional accuracy for objects that have cross-sectional shape. It can also produce other shapes such as hollows, semi-hollow, round tubes, etc., so long as they are of uniform cross-section.

Disadvantages of Extruded Aluminum

Some disadvantages of extruded aluminum include;

• Not Suitable for High Volume Production

If you’re looking into mass production, then the extruded aluminum manufacturing process shouldn’t be your first choice. The method is more suitable for customized, low medium production,hence isn’t the best choice when comparing extruded aluminum vs cast aluminum.

• Limited Material Choices

The extrusion process is not suitable for a large range of materials. While it can be used for most aluminum alloys, not all materials can be extruded, limiting the use of this process, and making the aluminum option a better casting choice.

• Limited Shapes and Sizes  

When considering complexities of shape to be produced between cast vs extruded aluminum manufacturing process, extruded aluminum has limited working abilities. The extrusion process can only produce cross sectional shapes, and can not produce shapes of large sizes beyond the sizes of the billets.

Different Between Extruded Aluminum vs Cast Aluminum

List their differences in a table and compare thWhile they are both good manufacturing processes, there are numerous differences between cast aluminum vs extruded aluminum. These differences can be found in the process, finished product, etc. Some f the include;

S/N	Difference	Cast Aluminum	Extruded Aluminum
1	Shape Produced	The aluminum cast process allows for production of complex shapes and forms, making it the best choice for products with complicated designs.	Extruded aluminum only allows for production of cross section shapes.
2	Cost Implication	The initial cost of set-up is quite expensive but can be made up over time.	The set-up is not very expensive.
3	Quality of Finished Products	Finished products from cast aluminum are usually prone to porosity, not as tough, and require surface finishing.	The finished products from extrusion are typically harder, and require less machining.
4	Size of Products	The size of finished products are flexible and range from small to very large products such as engine parts.	The size of finished products are usually restricted by the limited billet sizes.
5	Application of Products	Commonly used for complex automotive machine parts.	Due to the strength of finished products, it is applied in production of sturdy propellers and beams.

Aluminum Die Casting Service in Raidy Mold

Aluminum die casting is among the commonly used manufacturing processes for a number of reasons. With properties such as its lightweight, and temperature resistant properties make it excellent for mechanical manipulation. All of this mechanical manipulation such as fabrication, design, maintenance, and production of complex metal forms are services provided effectively and efficiently at Raidy Mold.

With the right machinery, equipped facilities, and full technical skilled team, Raidy Mold provides other additional services such as CNC machining, surface finishing, etc. They go the extra mile by testing for defects in finished products to correct them before delivery, as well as guarantee using only the best materials by sourcing for the best suppliers in the market.Using diverse surface finishing options such as matte finish, laser carving, shot blasting, Raidy Mold uses this method to strengthen the outer surface, while also improving the durability and performance of the finished products.

These finished products have numerous industry applications such as the automotive industry, communications components, mechanical and electrical components, etc. The amount of precision, professionalism, speed, and quality assurance ensured throughout the entire process, makes them one of the best options for all die casting services.

Conclusion

This article has helped you understand cast aluminum vs extruded aluminum, its meaning, how it works and the various advantages and disadvantages involved. Understanding this would help you make the decision on the right manufacturing process to use depending on your desired finished products. Deciding to use aluminum casting will require you to use reliable, experienced die casting manufacturers like Raidy Mold. 
With 30 years experience in the industry, Raidy Mold offers a large range of die casting services, with skilled experts, machinery, and resources for a wide range of products, and continuous production. This makes them experts in the field and suitable to provide you all your die casting needs. Contact Raidy Mold now, to get the best die casting services for your long and short term production projects.