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Die casting is a process wherein molten metal is forced into a mold cavity under high pressure. This results in the creation of parts with exceptional dimensional accuracy and smooth surfaces. Structural die casting specifically refers to the production of components that bear significant structural loads, making them essential in high-performance applications. The metals commonly used in this process include aluminum, zinc, and magnesium, each offering its unique properties in terms of weight, corrosion resistance, and strength.

The green sand mold is made by compacting the sand mixture into a two-part mold. The compacted sand forms a cavity corresponding to the desired shape of the cast component. Once the mold is prepared, molten aluminum is poured into the cavity, where it cools and solidifies to create the final product.

Aluminum investment casting, also known as lost-wax casting, is a sophisticated manufacturing process that enables the production of complex and high-precision metal parts. This technique has gained popularity across various industries, including aerospace, automotive, and medical, due to its ability to produce intricate designs with excellent dimensional accuracy and surface finish. Understanding the aluminum investment casting process involves exploring its steps, benefits, applications, and considerations.

The safety factor is usually between 1.5 and 2, depending on the material and application.