THORS eLearning Solutions

Aluminum Casting Fundamentals


Aluminum Casting Fundamentals introduces the learner to the properties, chemistry, and processes associated with casting aluminum components
Learning Hours: 2

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Course Description

Aluminum Casting Fundamentals introduces the learner to the properties, chemistry, and processes associated with casting aluminum components. The common aluminum casting defects are also included to familiarize the learners with real world problems that may arise in the production of aluminum casted parts. Presented in the THORS visual and interactive format, this course is relevant for learners who are new to the industry, as well as experienced learners that require a deeper knowledge of aluminum casting microstructure, casting grades, and microstructure control.

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Who will benefit from this Aluminum Casting course?

Foundries that melt aluminum; Customers who procure aluminum castings; Organizations that sell raw materials, equipment, and services to aluminum foundries.

Course Classification

This manufacturing course by THORS eLearning Solutions covers identification of key terms and understanding of key concepts.

*THORS uses the Bloom’s Taxonomy Methodology for our course development.

Certificate Awarded for Aluminum Casting Fundamentals

Example of certificate awarded upon successful completion of the course.

*upon successful completion

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Learning Objectives

  1. Recognize the aluminum casting mechanical properties and chemistry.
  2. Understand how to interpret the aluminum-silicon (Al-Si) phase diagram.
  3. Identify the various aluminum casting grades utilized for application-specific purposes.
  4. Recall the common aluminum casting terminology.
  5. Differentiate between the different types of casting processes.
  6. Identify the types of possible casting defects that occur during aluminum casting production.
When added to aluminum alloys, titanium and boron adjust the grade and properties to serve a specific purpose.
Aluminum Casting Fundamentals

Table of Contents

  1. Aluminum Casting Properties
    1. Aluminum Casting Mechanical Properties
      1. Hardness
      2. Strength
      3. Ductility
      4. Fracture Toughness
      5. Machinability
      6. Conductivity
      7. Corrosion Resistance
    2. Aluminum Alloy Chemistry
      1. Silicon
      2. Copper
      3. Magnesium
      4. Zinc
      5. Tin
      6. Titanium
      7. Boron
      8. Iron
      9. Sodium
      10. Strontium
      11. Antimony
      12. Phosphorus
      13. Manganese
    3. Al-Si Phase Diagram
    4. Cast Alloy Designations
    5. Aluminum Casting Grades
      1. General Purpose Alloys
      2. High Temperature Alloys
      3. Wear Resistant Alloys
      4. Moderate Strength Alloys
      5. High Strength Alloys
  2. Aluminum Casting Processes
    1. Casting Terminology
    2. Bonded Sand Molding
      1. Ablation Casting
      2. Cosworth Process
    3. Permanent Mold Casting
      1. Gravity Die Casting
      2. Tilt Casting
      3. Low Pressure Die Casting
    4. High Pressure Die Casting
    5. Squeeze Casting
    6. Investment Casting
    7. Semisolid Casting
  3. Casting Defect Analysis
    1. Aluminum Casting Microstructure
    2. Microstructure Control
      1. Grain Refinement
      2. Silicon Modification
    3. Porosity
      1. Gas Porosity
      2. Shrinkage Porosity
    4. Inclusions
      1. Types of Inclusions
    5. Hot Tearing
    6. Lap Defects
      1. Oxide Laps
      2. Cold Laps

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