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Unlocking the Strength of A356: How Digital Metal Casting Delivers Superior Tensile Properties
In the world of metal casting, achieving superior mechanical properties while maintaining efficiency and cost-effectiveness has long been a challenge. Foundry Lab’s Digital Metal Casting (DMC) process is changing the game by delivering A356 aluminum alloy parts with tensile properties that rival traditional permanent mold casting, without the need for expensive tooling or lengthy production timelines.
Our latest research explores the hardness and tensile properties of DMC-cast A356 in both as-cast (F) and T6 heat-treated conditions. Here’s what we found.
Superior Tensile Properties: DMC vs. Traditional Casting
We cast A356 “Characterization” castings and tensile bars using Foundry Lab’s Melt-in-Mold process, which combines binder jet 3D-printed ceramic molds with vacuum-assisted casting. By digitally controlling parameters like mold design and solidification rates, we were able to achieve exceptional mechanical properties, without the complications of shut-off and underfilled parts.
Key Finding: DMC significantly outperforms typical sand casting properties in both as-cast and T6 conditions. In fact, the tensile properties of DMC-cast A356 are on par with permanent mold castings, a major breakthrough for rapid manufacturing and prototyping.
Optimizing Strength and Ductility with Heat Treatment
Heat treatment plays a critical role in balancing strength and ductility in A356. We explored the effects of:
- T64 (Underaged) Treatment – 540°C for 4 hours, warm water quench, 160°C for 4 hours
- T6 (Peak Aged) Treatment – 540°C for 4 hours, warm water quench, 180°C for 4 hours
What We Found: A T64 heat treatment increases ductility, but slightly reduces strength compared to the T6 condition. By adjusting artificial aging parameters, manufacturers can fine-tune mechanical properties to suit their needs.
The Role of Mold Design in Strength & Porosity Control
Mold design is critical in minimizing shrinkage porosity, which directly affects mechanical performance.
Key Finding: Mold designs that result in higher shrinkage porosity reduces strength and ductility of the casting.
This shows that mold design can be optimized to improve casting quality and mechanical properties—without additional processing steps.
Solidification Rate: How Cooling Affects Strength
The DMC process uses inert gas quenching to control solidification rates. Slower cooling leads to larger grain structures and increased Secondary Dendrite Arm Spacing (SDAS), which negatively affects strength and ductility.
Key Finding:
- Faster solidification leads to higher tensile strength and better ductility.
- This effect is most noticeable in the as-cast condition, though T6 properties also benefit.
Mold design can also be used to increase solidification rates by employing thinner wall thickness designs.
Conclusion: Why DMC is a Game Changer for A356 Casting
Our findings confirm that Digital Metal Casting (DMC) delivers A356 aluminum parts with superior mechanical properties—faster and more efficiently than traditional foundry methods.
- DMC A356 outperforms sand casting and is comparable to permanent mold casting.
- Heat treatment parameters can be adjusted to tailor strength and ductility.
- Mold design plays a critical role in minimizing shrinkage porosity and increasing solidification rates, therby improving mechanical properties.
With DMC, manufacturers gain control over lead times, costs, and quality—without relying on traditional foundries. Whether for rapid prototyping or low-volume production, Foundry Lab’s Digital Metal Casting process is redefining what’s possible with A356 aluminum.
Interested in learning more? Join us for our first Materials Lab webinar. Register now!
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