Machined Aluminum vs. Cast Aluminum: Which Is Right For ...

Machined Aluminum vs. Cast Aluminum: Which Is Right For Your Project?

What Is Machined Aluminum And Cast Aluminum?

Machined aluminum parts are common in various manufacturing industries and are typically produced using CNC machining procedures such as CNC milling, grinding, and CNC turning. Of these methods, CNC milling is the most prevalent due to its capability to achieve complex designs.

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CNC aluminum is prized for its properties like low density and high strength, making it versatile for many applications. Different aluminum alloys used in machining include:

• Aluminum 6061: Known for its mechanical strength, weldability, and ability to withstand harsh conditions.
• Aluminum 7075: Noted for high fatigue resistance and wear, though it is more costly and less suitable for welding.
• Aluminum 2024: Common in aerospace and military industries due to its tensile strength but has low weldability and corrosion resistance.

Other alloys like aluminum 2014, 5052, and 6063 are also viable for CNC machining.

Conversely, cast aluminum is produced by melting aluminum and pouring it into molds. This process can use various casting methods such as die casting, sand casting, and more. Common alloys for casting include:

• A380: Lightweight, heat-resistant, and durable, making it suitable for complex parts.
• A383: Good conductor of heat and corrosion-resistant, but slightly less durable than A380.
• A360: Highly ductile and corrosion-resistant, but challenging to cast.

The Benefits Of Machined Aluminum

Machined aluminum offers numerous advantages:

Complex Shapes and Precision

Techniques like CNC milling and turning allow for precision and accuracy, ideal for intricate parts used in automotive and aerospace sectors.

High Corrosion-Resistance

Machined aluminum forms a protective oxide layer, reducing corrosion and maintenance costs.

High Strength and Lightweight

Its lightweight yet strong nature makes machined aluminum perfect for structural applications, particularly in aerospace.

Good Conductivity and Temperature Resistance

Aluminum's ability to conduct heat and electricity broadens its applications, supported by its high-temperature resistance.

The Benefits Of Cast Aluminum

Cast aluminum is valued for:

Versatility

Cast aluminum can be machined further, adding to its versatility.

Cost-Effectiveness

It’s generally cheaper to produce compared to CNC machined parts.

Long Lifespan

Its resistance to rust and wear extends its durability and lowers maintenance costs.

Environmentally Friendly

Cast aluminum is recyclable, making it a greener choice.

When to use machined aluminum vs. cast aluminum

Choosing between machined and cast aluminum depends on specific project needs. Key considerations include:

Aluminum Types and Alloys

Machined aluminum uses alloys like 6061, 7075, and 2024, while cast aluminum utilizes A360, A380, and A383.

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Appearance

Cast aluminum is versatile for creating complex shapes, similar to injection molding. Machined aluminum is ideal for items requiring minimal design changes.

Conduction of Heat

Cast aluminum has a thermal conductivity of about 90 w/m.k, whereas machined aluminum offers 180–190 w/m.k, making it better for high-heat applications.

Cost and Prices

Machined aluminum tends to be more expensive due to the machining processes involved. Proper cost calculations are essential for each project.

Level of Output

Cast aluminum suits high-volume production, while machined aluminum is ideal for lower volumes, often under 1,000 parts per day.

Applications

Uses of machined aluminum include downlights, ceiling lamps, and structural components. Cast aluminum is commonly used for automotive parts, street lamps, and mobile devices.

Conclusion

When choosing between machined and cast aluminum, consider your project’s specific needs and budget to make the best decision.

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What is the Difference Between Extruded Aluminum and Cast Aluminum?

Aluminum is versatile for both extrusion and casting. Extrusion involves forcing aluminum billets through a die, whereas casting involves pouring molten aluminum into a mold. Both methods offer cost savings by reducing machining time. At Howard Precision Metals, we can guide you in deciding the best method for your needs.

Extrusion: An Economical Manufacturing Process

Aluminum extrusion is cost-effective for intricate designs and offers excellent surface finishes. However, it is limited by the size of the billet and the extrusion press. Products like heat sinks, window frames, and lighting equipment are commonly made through extrusion.

Aluminum Casting

Aluminum can be cast using various methods, such as die casting and sand casting. Casting is slower compared to extrusion and may require additional processes to remove mold imperfections. Despite its slower pace, casting remains popular for products like cookware and automotive components.

Advantages and Disadvantages of Both Casting and Extruding Aluminum

Casting may have higher initial costs but is more economical for high-production runs and intricate designs. Extrusions are stronger and have no porosity, making them suitable for parts with simpler designs. Both methods have unique advantages that suit different applications.

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