Aluminum Metalcasting 101


"This course was exactly what I hoped it would be with an explanation of basic aluminum alloys and uses."


Upcoming Courses


Participants in this introductory course will develop their knowledge of aluminum’s characteristics and properties, the use of appropriate alloying elements, latest industry applications, and important considerations when working with cast aluminum parts. Course materials include the latest information in melting and casting technology and the decision-making process for choosing specific technologies.

This course has been created for industry personnel looking to establish or enhance their knowledge in the practical and theoretical knowledge of the aluminum metalcasting business. It provides a comprehensive foundation of the aluminum casting processes, treatments, and practical applications, and leads participants through critical process decisions that affect final product cost. This course serves as a prerequisite for other aluminum courses.

Learning outcomes

Course participants will learn to identify:

  • Principle properties of aluminum
  • AAUS alloy classification system
  • Role of alloying elements in aluminum castings
  • Aluminum alloys for specific applications
  • Common aluminum melting methods
  • Common molding/casting methods for aluminum

Course Length

1.0 day

CEU Units

0.60 CEU

Course outline

Module 1: Introduction
Module 2: Overview of Aluminum Processing

•    Where Are Aluminum Castings Used?
•    Aluminum Processing

Module 3: Aluminum Properties

•    Basic Atomic Structure
•    Mechanical Properties
•    Physical Properties

Module 4: Alloying Elements

•    AAUS Alloy Designation System
•    Effects of Alloying Elements

Module 5: Applications of Aluminum Alloys

•    General Applications of Alloy Families
•    Alloy Selection

Module 6: Aluminum Melting Technology

•    Introduction to Aluminum Melting Technology
•    Safe Handling of Molten Aluminum
•    Furnace Types
•    Melt Process Overview
•    Impurities
•    Melt Treatments

Module 7: Aluminum Metalcasting Technology

•    Sand Casting
•    Permanent Mold Casting
•    Die Casting
•    Investment Casting
•    Lost Foam Casting
•    Case Study
•    Heat Treatments

Module 8: Conclusion