Casting

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Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold setting materials.

In metalworking, metal is heated until it becomes liquid and is then poured into a mold.

 

Sand casting is a metal casting process characterized by using sand as the mold material.

    Suitable materials: steel, iron, and various nonferrous metal.

    Pros and cons:

    1.  Suitable for products with very complex shapes, especially complex inner cavities.

    2.  Broader application range, and relatively low cost

    3.  Good for components or blank made from cast iron

    Applications:

    Cylinder block, cylinder head, crank shaft of engine of automobile

 

 

Investment castingit is an industrial process based on lost-wax casting, one of the oldest metal-forming techniques

    Suitable materials: Almost any metal can be cast

    Pros and cons:

    1.  Excellent surface finish

    2.  High dimensional and geometric accuracy

    3.  Extremely intricate parts are castable

    4.  No flash or parting lines

    5.  Sophisticated process and high manufacturing cost

    6.  Longer production cycles compared to other casting processes

    Applications:

    Turbine blades with complex shapes or cooling systems in aerospace and power generation industries.  Firearm receivers, triggers, hammers, and other precision parts at low cost in                firearm industries. Other industries include military, medical, commercial and automotive.

 

Gravity die casting : it is the process for fabricating metals and metal alloys. It involves the pouring of molten metal from a crucible into a mold under only the force of gravity, without the use       of pressurized gasses, vacuums.  It is named permanent mold casting or chill casting.

    Suitable materials: aluminum, magnesium, iron, steel

    Pros and cons:          

    1.  the surface is better than sand casting

    2.  weight range from 30g to 100kg/pcs

    3.  Thickness of parts must meet above 3.5mm, the draft angles must meet 1º to 3º on outside surface, 2º to 5º on inside surface.

    Applications:  wheels, automotive, subway, gas station, pipeline components, fuel injection housings, spline.

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