Did you know that all of the aluminium components used in industries across the world have been created through a casting process? The molten metal is poured into molds where it sets and becomes the different shapes and forms that are needed for construction and other industrial applications. But what types of molds are used to cast aluminium and how does each work?

• Sand Casting: This is the oldest type of mold for casting aluminium; it was being used back in the time of the ancient Egyptians. Sand is held in a box and a cavity is created (using a solid material, like timber) whereby the molten metal is poured in. 
• Ceramic: This mold is created around a plastic or wax shape that melts when the mold it fired. Once the wax or plastic has melted away, the mold is ready to receive the molten aluminium. This process is also known as ‘precision casting’. 
• Permanent Casting: These molds are crafted from metals like steel and iron. The aluminium is forced into the cavity, using either gravity or a vacuum. The difference with these molds is that they can be reused again and again. 
• Die Casting: These molds use steel dies to produce a number of castings that are identical. Under high pressure, the molten aluminium is forced into these cavities. It is favoured for being a versatile process, enabling the creation of small to medium castings. 

In part two of this blog, we will take a closer look at some of the other molds that are commonly used in aluminium casting, including shell, plaster and graphite casting ones. These are known for being a little more complex and uncommon than the four outlined above.

Many people wrongly assume that the same tools used to work iron can be used to work aluminium. As it is a much softer metal, however, it is important that you use tools that will take this into account. Fortunately, many of the tools used for woodworking can be used on this metal.

• Saws
  Hand-held or hacksaws can be used on aluminium, providing that you have chosen the right kind of blade. They need to have wide-mouthed teeth and must be made out of carbide to ensure precise cuts.
• Center Punch
  This is a sharp rod made out of iron that is used for making marks on metal. On aluminium, it is used to etch cutting edges and to mark the position of holes.
  
  
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  Drills
  Hand-held drills are highly useful for working with aluminium, providing that you use a drill bit with wide spirals (to prevent the metal from clogging the bit).
• Mallets
  You cannot use a hammer on aluminium, as it will create dents. Instead, use a wooden mallet. They can be used for shaping a sheet, fixing it in place or even for hammering in rivets.
• Screwdrivers
  You don’t need special screwdrivers for working with aluminium - your standard ones will be fine, providing that they fit into screws that are Phillips O, Phillips Square, Phillips O Hex, Cheese or Rounded head.
  
  

Once you have finished working your aluminium, there will also be a wide range of buffing and polishing tools available to you to ensure that the shine of the metal is brought back. The tools outlined above, however, are likely to be on hand for most homeowners.