Metal Casting Zone Info Blog

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Information about various Castings Process and Types

Casting history is older than 6000 years. A casting is also known is molding process in which any metal is poured in to the mold. It is one type of manufacturing process in which every metal poured in mold. Generally, casting is uses for creating desired an most intricate of shapes..

Casting can remove other operational processes like machining, forging, and welding. There are different types of casting method or process available today. Generally casting process is divided in to 2 types expendable casting and non-expendable mold casting.Temporary and non-reusable molds are used in expendable casting process. Sand casting, Plaster Casting, Shell Molding, and Investment Castings process are one of the expendable casting processes.

This is oldest metal forming or casting process. Lost wax casting used for to manufacturing of huge parts like turbocharger wheels, golf club heads, elect huge variety of parts ranging from turbocharger wheels to golf club heads, from electronic boxes to hip replacement implants. Lost wax casting used for investment castings. Today investment castings are used for aircraft engine and airframe parts. Lost wax casting is similar to the Lost Foam Casting in which expendable foam patterns are uses for casting productions. Foam pattern is remaining in mold during metal pouring and it’s replaced by molten metal

Die Casting Die casting is one of the non expandable casting process. It’s one type of process in which molten metal is forced under high pressure into mold cavities. In die casting mold dies is used again and again for producing variety of casting size, shape and thickness. Parts, which are manufacturing by die casting are heat resistance and maintaining close tolerances. Die casting produces parts with thinner walls, closer dimensional limits, and smoother surfaces

Sand Casting Sand casting used for make large parts. In sand casting sand used with mold. In sand casting cavity is formed by wood or metal pattern. Using sand casting method, you can cast large iron bell, and alos small automotive parts. In sand casting, two types of sand used like green sand, which is mixture of silica, and olivine sand. Sand casting is uses for high volume production

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Information about Cast Iron and Its Benefits

Cast iron known as gray iron and it is one of the famous ferrous alloys for iron and metal industry. In cast iron carbon ( c) and silicon (s) are the main element with the amount of 2.1 to 4 wt% and 1 to 3 wt% respectively. Also you can mix Cr, Ni, Mo and Cu according to your requirement.

In India many Investment casting foundry used different ferrous metals such as carbon steel, alloy steel, stainless steel, cast iron for castings which formally known as ferrous castings. But they mostly prefer cast iron with its different compositions including white cast iron, gray cast iron, malleable cast iron, ductile iron etc. See below some basic description for above compositions.

White Cast Iron

White cast iron contains lower silicon and metastable phase cementite, Fe3C rather than graphite. It offers hardness with the rate of toughness. Generally white cast iron classified as cermet. Cast iron is used for structural components manufacturing for good hardness with low cost. Also it used for manufacturing or industrial parts such as slurry pumps, shell liners and lifter bars in ball mills and grinding mills, and the teeth of a backhoe’s digging bucket.

Grey Cast Iron

These types of cast iron characterize by its graphitic microstructure and its widely used cast iron based on weight. Cast iron having 2.5 to 4.0% carbon, 1 to 3% silicon so it’s pure iron also contain less tensile strength and shock resistance than ductile iron or malleable iron and its compressive strength is low then carbon steel. Many casting foundries used gray cast iron to manufacturing some general engineering components such as protective cover, cover, oil pan, hand wheels, frame, floor, hammer, small handle, machine base, frame, box, knife, bed, bearing seat, table, wheels, cover, pump, valve, pipe, flywheel, motor blocks.

Malleable Cast Iron

Its properties are same as mild steel property and it is heat treated iron with carbon alloy which solidifies with graphite free structures means carbon is present in the cemnetite form (Fe3C). This type of cast irons contains different chemical element composition such as carbon, silicon, manganese, sulfur, phosphorus etc. Also it possesses considerable ductility and toughness

All of the above cast iron compositions are widely used for making high quality and higher resistive part for industries. Also auto parts manufacturers in India widely used cast iron for making higher strength and corrosion free automotive parts with help of auto component castings

ductile iron & gray iron castings foundry in the USA. Mabry Castings LTD, www.mabrycastings.com

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Information about Metal Casting and its Benefits

Metal casting is the process in which various metals like aluminum, steel, stainless steel, copper-base alloys and iron are poured in to mold for making desired shape and solidify. This solid part is known as casting and it is ejected when molding process is completed. In metal casting wide variety of material use as molds but condition is this material is to be durable, and strong and also it’s easily withstand with hot metals. Means it is not burning during molding process. Materials like Wood, limestone, plaster of Paris, and ceramic are widely used in metal casting.

These molding materials are re-usable means its use in molding process for more and more time. In India, various casting foundries uses hot furnace or forge for directly metal blacksmithing, or melts for metal casting india. Once when metal is molten it can be alloyed with other metal like aluminum, steel and this mixture is carefully poured in molds for metal casting. In India, leading casting foundries uses various metals casting process like sand casting, investment casting, steel casting, ferrous casting etc.

Advantages of Metal Casting

Metal casting us used for manufacturing engineering parts or objects
Automotive parts, pipe, and metal castings manufacture fittings, constructions, mining, oil field equipment, and internal combustions engines part.
For government sector, metal casting is uses military vehicles parts like tank, truck, jet engine and other vital components.
Metal casting is uses as designed mechanical products for parts with variety of strength.
Also used in various steps like machining, forging, and welding.
Enables to mold the products into one single unit than manufacturing different parts and assembling those means you do not need to separate manufacture of different parts
Through metal casting, you can exhibit the same properties regardless of which direction is select.
Metal casting is uses for Wide range of alloy compositions and properties are produced in cast form.

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It is a Mantua corporation cast aluminum silver streamliner ho scale. It’s markings on the side of the cars are “Long Island Rail Road’. Can someone please help me with this?