Types of Casting Processes in the Manufacturing Industry

There are many different types of casting processes in the manufacturing industry. Each of these allows manufacturers to produce the products they desire with precision and high quality.

Casting is the process of forming metal parts from molten metal into pre-designed shapes. It offers many benefits, including cost savings and scalability.

Sand Casting

Sand casting involves forming a mold from sand, a cheap and refractory material. This process is able to cast virtually any alloy.

The first step in sand casting is to create the foundry pattern. This is a replica of what the final part will look like. This can be done either by carving directly into the sand or 3D printing for precision casting.

Next, the sand is poured in a flask (the box) that holds both the upper and lower mold parts, also known as drag and cope. The sand is then packed around the patterns in each half of the flask to form a mold cavity.

This can be done by hand or machine. However, pressure or impact is the best way to pack sand.

Once the sand mold is created, the final metal piece can be melted and poured into it. The molten metal will cool and solidify, creating the casting.

Pressure Casting

There are several types of casting processes in the manufacturing industry, including sand, high-pressure die casting, lost wax and spinning casting. Each type of metal has its own advantages and disadvantages.

Sand casting is the most common casting process used in specialized factories, where a mold made of sand is poured with molten metal. Typically, this process is more cost-effective than low pressure and spun casts because the extra materials can be reused after the finished product is produced.

image source https://www.pinterest.ph/

Squeeze casting is a single-step process that combines the benefits of casting and forging. It produces parts that have better mechanical and finishing properties than traditional casting methods.

The molten metal is injected into the squeeze-casting machine for hydraulic cylinder patrs through a vertical or horizontal shot sleeve. This reduces contact between the injector and the molten steel, which can help to prolong the life of the components. It also reduces the tendency for entrainment of air during injection, which can lead to gas porosity.

Spinning casting

Spin casting is a precision production process that produces high integrity, close tolerance parts. It produces wax, metal, and plastic parts with precise details. It also accommodates undercuts and preserves the surface texture.

Using a spin-casting machine, metal is poured into the mold and spun at high speeds. The centrifugal force pushes liquid into all cavities in the rubber mold due to the pressure.

The resulting cast is then inspected and analyzed for defects. Then the part is ready for painting, plating or coating.

The spin casting process can produce thousands, hundreds, or even thousands of parts per hour. It is cost-effective and quick to cast parts. This can be used to troubleshoot engineering design issues before investing in hard tooling.

image source https://www.pinterest.ph/

Lost Wax Casting

The lost wax casting process (also known as investment casting) is one of the oldest metal-forming techniques. It is still used in manufacturing and fine art.

It can be used on a variety metals like brass, bronze and iron. It creates parts with thin walls, intricate details, and close tolerances.

The aerospace industry uses wax-cast parts for hardware like brackets and valves with steel investment casting parts. These components are made to withstand high temperatures and pressures.

Medical devices are another application for the lost wax casting process. These products have to be manufactured to precise standards and must meet regulatory specifications. They are also able to withstand harsh environments and high levels of wear.