Casting

Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. The process is to pour molten metal 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.

The casting process is divided into two main categories: expendable and non-expendable casting. In expendable casting, a mold is temporary and non-reusable, and is needed to be reformed in each production cycle, while in non-expendable casting, a mold can be reused in all production cycle.

Here are some common casting processes we are capable of providing to you:

• Expendable mold casting

  • Sand casting
  • Investment casting

• Non-expendable mold casting

  • Die casting
  • Permanent mold casting

Sand casting

Sand casting is the most used casting process of all metal castings. This process places a replica of the final workpiece in sand to create a mold. The advantage of sand casting is that molds made of sand are relatively cheap and sufficiently refractory. Also, sand casting allows for smaller batches at a reasonable cost. Sand casting allows most metals to be cast.

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Investment casting

Investment casting is also known as "lost-wax casting". This process invests the pattern (a replica of the final workpiece made in waxes) with refractory material (e.g. ceramic) to create a mold. Often, several molds are assembled into a tree to allow casting several pieces simultaneously. The advantage of investment casting is that products come with great surface qualities, which can reduce the need for secondary processes. The disadvantage is the relatively high cost for short-run productions. Investment casting allows most metals to be cast.

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Die casting

Die casting forces molten metal under high preesure into a mold cavity. Die casting has large capital costs, but it is suited for small to medium size castings that require good surface finish and dimensional consistency.

The typical materials used in die casting are non-ferrous metals, such as:

• Zinc (Zn)
• Copper (Cu)
• Aluminium (Al)
• Magnesium (Mg)
• Lead (Pb)
• Tin-based alloys (Sn)

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Permanent mold casting

Permanent mold casting, sometimes referred to as gravity casting, uses gravity to fill reusable molds. The advantage of permanent mold casting is the reusable mold. Permanent mold casting is used to manufacture gears, splines, wheels, gear housings, pipe fitting, fuel injection housings, and automotive engine pistons. The typical materials used in permanent mold casting are:

• Aluminum (Al)
• Magnesium (Mg)
• Copper (Cu)
• Tin (Sn)
• Zinc (Zn)
• Lead (Pb)
• Iron (Fe)
• Steel

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