According to customer requirements, we manufacture steel components by different types of metal casting methods from small to large steel parts such as spare parts, punched parts, laser parts, complex components, box dumpers, and special designs. No matter what casting method your project requires, our factories consistently deliver high-quality cast metal products that meet or exceed expectations.
What are 3 popular types of metal casting?
Sand casting is one of the most popular and simplest types of metal casting, and has been used for centuries. Sand casting allows for smaller batches than permanent mold casting and at a very reasonable cost. Not only does this method allow manufacturers to create products at a low cost, but there are other benefits to sand casting, such as very small-size operations.
The process allows for castings small enough fit in the palm of one’s hand to those large enough only for train beds (one casting can create the entire bed for one rail car). Sand casting also allows most metals to be cast depending on the type of sand used for the molds. Over 60% of all metal castings are produced via sand casting process.
In general, we can distinguish between two methods of sand casting; the first one using green sand and the second being the air set method.
The sand is bonded using clays, chemical binders, or polymerized oils (such as motor oil). Sand can be recycled many times in most operations and requires little maintenance.
The die casting process forces molten metal under high pressure into mold cavities (which are machined into dies). Die casting requires two larges, moving non-ferrous metal parts that clamp together under high-pressure. Molten metal is injected into the die and the metal parts are separated once hardened.
Most die castings are made from nonferrous metals, specifically zinc, copper, and aluminum-based alloys, but ferrous metal die castings are possible. The die casting method is especially suited for applications where many small to medium-sized parts are needed with good detail, a fine surface quality and dimensional consistency.
The process of investment casting begins with filling a mold with wax. Once the wax hardens, it is coated multiple times in a ceramic material. This is heated until the wax melts and the ceramic mold remains. The mold is filled with molten metal, cooled, and then the ceramic material is broken off.
Beside 3 main types we mentioned, there are still some types of metal casting methods which are using around the world with a small quantity every year.
AM Industries Vietnam’s metal casting services
A pattern is a replica of the exterior of the casting. Patterns are typically made of wood, metal, plastic, or plaster. Patternmaking is incredibly important for industrial part-making, where precise calculations are needed to make pieces fit and work together.
If a casting is hollow, an additional piece of sand or metal (called a core) shapes the internal form to make it hollow. Cores are typically strong yet collapsible so they can be easily removed from the finished casting.
To visualize the metal casting process so far, imagine yourself walking on the beach toward the ocean. Look at a footprint you leave behind in the wet sand. Your foot would be the core, and the impression left in the sand is a mold of your foot. Molding is a multistep process that will form a cast around the pattern using molding sand. In casting, a mold is contained in a frame called a flask.
Green sand, or molding sand, is packed into the flask around the pattern. This is known as metal sand casting. Once the sand is packed tight, the pattern can be removed and the cast will remain.
Alternatively, a two-piece, non-destructible metal mold can be created so that the mold can be used repeatedly to cast identical parts for industrial applications.
After metal is melted, it is poured into the cavity of the mold and left to solidify. Once solidified, the shakeout process begins: the molds undergo vibration to remove sand from the casting.
In industrial applications, our equipment keeps production output high because of its efficient and smooth performance. Removed sand is typically collected, cooled, and reclaimed to be used once more in future castings.
Our Sand Casting Conditioner improves this process of sand separation from castings by removing and cooling sand and castings and evaporating moisture, while alleviating the casting damage that is common during this point of the process. The end results are a clean cast and sand ready for the reclamation process.
In this final step, the cast metal object is removed from the mold and then fettled. During the fettling, the object is cleaned of any molding material, and rough edges are removed.
Additional resources:If you want reliable steel fabrication – steel spare parts – steel components, contact the experts at AM Industries Vietnam. Our processes include stamping, welding, folding, bending, and finishing to match our exact requirements.
Working as a solution provider, at AM Industries Vietnam, we are completely focused on our approach and it is reflected in our business process. Due to our committed approach, we are highly trusted by our clients. Contact us here to get the best quote!
There are a range of different types of traditional casting methods available. Casting is a manufacturing process that is typically used to create hollow and intricate shapes. The process involves liquified materials in which it is poured into the cavity of a specially designed mold and allowed to harden. Each type of casting and the individual casting processes provide their own benefits and it’s recommended to explore different methods available before deciding on the casting method that you want to choose for the manufacturing process. Here at Precision Investment Casting, we specialise in Investment Casting but there are a whole host of other options that include;-
The investment casting process has been around for decades and PI Castings have over 65 years of experience manufacturing components through the investment casting process. Through our vast experience, wealth of knowledge and state-of-the-art casting machinery, we are able to accurately and successfully produce castings from both non-ferrous and ferrous metals. The process for investment casting is fairly straightforward with a proven 8-step process that starts in the wax room and finishes with testing where castings are carefully fettled, blasted and heat treated. Setting operations here may also be required.
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This type of casting method is ideal and recommended for producing castings in a sand mold, steel, iron and most non-ferrous alloy castings. The process of sand casting involves several stages in order to achieve a high quality finish. One of the first stages with sand casting may start with pattern-making which then proceeds to pouring, melting and cleaning. Sand casting is one of the most popular and most traditional types of casting methods that offers relatively inexpensive production costs when compared to other methods.
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Plaster casting isn’t too dissimilar to the sand casting process in the sense that it uses a mixture strengthening compound and gypsum with the real difference being the use of water as a substitute for the sand. With plaster casting, an anti-adhesive compound is applied to prevent mold from being stuck against it and the plaster is also capable of filling in any gaps too. When the surface finish is one of the most important requirements, plaster casting is recommended but it can be much more costly than other types of traditional methods such as sand casting.
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Die casting – also known as a metal casting process – is a proven and traditional casting method that normally involves non-ferrous metals which could include aluminium, copper, tin, copper and zinc. The high pressure metal liquid is pressed into a precision metal mold cavity at high speed and the metal liquid is cooled and solidified under pressure to form the desired casting. Die casting involves a highly technological process and whilst it is a proven method, it can also be a very costly one.
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If you’re looking to produce longer cylindrical parts such as cast iron pipe, the centrifugal casting process may be what you require. With this process, molten metal is poured into a rotating mold before the mold is then solidified and filled under the action of Centrifugal force. When it comes to manufacturing metal parts and components, Centrifugal is one of the go to traditional methods even to this day.
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This type of casting method shares numerous similarities with Centrifugal and die casting. Permanent mold casting involves a low pressure-process that can be done by hand or machinery using multiple molds on a turntable. This process involved simple equipment if required and really easy automation.
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Here at PI Castings, we provide high-quality and industry-leading investment casting. We are one of the longest serving manufacturers of investment casting in Europe with decades of experience. We highly recommend investment casting to create complex and detailed cast metal components for a variety of different applications and industries. Call us today on 0161 925 5160.
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