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Heat Treatment of Aluminum Castings - Process Comparison

Process Precision Sand Castings Rubber Plaster Molding Investment (Lost Wax) Castings Permanent Mold Graphite Permanent Mold Die Casting V-Process Castings
Typical Size Range oz.-100 lbs. oz.-30 lbs. oz.-20 lbs. oz.-100 lbs. oz.-10 lbs. oz.-30 lbs. Up to 150 lbs.
Tolerances ±.020" to 10", then add ±.001"/", thereafter. ±.010" to 8", then add ±.001"/", thereafter. ±.003" to 1/4" ?004" to 1/2" ±.005" to 3", then add ?003"/". ±.015"/" to 1", then add ±.002"/". ±.005" Add ±.002" across the parting line. ±.002"/" Add ±.015" across the parting line. ±.02" to 6", then add ±.002"/" Add ±.02" across the parting line.
  Add minimum of .010 " across the parting line and for cored features. Add minimum of .005" across the parting line and for cored features.   Add ±.010" to .030" across the parting line.      
Flatness Within .015" Within .010" Within .015"        
  (geometry dependent) (geometry dependent) (geometry dependent)        
Surface Finish 120-175 RMS, except on cored areas. 63-125 RMS 63-125 RMS 150-300 RMS 25 RMS or better 32-63 RMS 125-150 RMS
Minimum Draft Required 1/2° to 3° 1/2° to 2° None 2° to 4° 1° to 2° 1° to 3° None
Minimum Wall Section Typical: .140"-.187" Minimum:�.080" (geometry dependent) Typical: .100" -.187" Minimum:�.040" (geometry dependent) .060" .187" .100" .030" to .060" .125"
Typical Quantities All <2,000 <1,000 500 500-1500 2,500 All
Typical Tooling Price (N.R.E.) $800 - 4K $3K - 15K $3K - 10K $5K - 15K $1.5K - 5.5K $5K - 250K $3K - 6K
Nominal Lead Times Samples: 1 - 4 wks. Production: 1 - 5 wks. after�approval. Samples: 2 - 4 wks. Production: 1 - 5 wks. after�approval. Samples:2 - 4 wks. Production: 5 - 12 wks. after�approval. Samples: 8 - 20 wks. Production: 10 - 12 wks. after�approval Samples: 3 - 6 wks. Production: 2 - 4 wks. after�approval. Lifetime use. Samples: 12 - 26 wks. Production: 8 - 14 wks. after�approval. Samples: 2 - 6 wks. Production: 2 - 6 wks. after�approval.