Aluminium casting processes are classified as Ingot casting or Mould casting. During the first process of aluminium casting, primary or secondary aluminium is cast into rolling ingot (slab), extrusion ingot (billet) and wire bar ingot which are subsequently transformed in semi- and finished products.

The second process of aluminium casting  is used in the foundries for producing cast products. This is the oldest and simplest (in theory but not in practice) means of manufacturing shaped components.

This page exclusively describes some methods of aluminium casting which can be divided into two main groups :

• Sand casting
• Die casting

Other techniques such as "lost foam" or "wax pattern" casting processes are also used but their economical importance is considerably lower than both listed techniques.

In sand casting, re-usable, permanent patterns are used to make the sand moulds. The preparation and the bonding of this sand mould are the critical step and very often are the rate-controlling step of this process. In sand casting, two main routes are used for bonding the sand moulds:

• The "green sand" consists of mixtures of sand, clay and moisture.
• The "dry sand" consists of sand and synthetic binders cured thermally or chemically.

The sand cores used for forming the inside shape of hollow parts of the aluminium casting are made using dry sand components.

Normally, such moulds are filled by pouring the melted aluminium in the filling system. Casting Mould designing is a particularly complex art and is based on the same principle as gravity die casting

Aluminium die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

Aluminium die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Aluminium die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.

Dimensional accuracy and stability - Aluminium die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant.

Strength and weight - Aluminium die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because aluminium die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.

Multiple finishing techniques - Aluminium die cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.

Simplified Assembly - Aluminium die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.

In high pressure die casting , the liquid aluminium is injected at high speed and high pressure into a metal mould.