Metal Casting Zone Info Blog

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Foundry: Metal Casting

Metal casting is what the name suggests. Basically metal casting is the process of melting down metal into a liquid state. The liquid metal is then poured into a cast; this cast allows the metal to cool creating the desired result of the intended mould or specific item they wish to make out of metal. The finished product is then sent off to be polished up and ready to be distributed.

Metal casting is used for more “tailor-made” areas of manufacturing metal products which would generally cost a whole lot more if they had to be machined welded. A great aspect of Metal casting is that it also allows the ability to re-create the same product with great ease and they products are identical of one another.

The most important and integral part of metal casting is the mould. The mould is essentially what the product is going to be. These moulds are manufactured in a foundry. Manufacturers take their dimensions, sketches and ideas for the mould to the foundry where the moulds are produced. These moulds then get sent off to the casters. Casters put the completed mould into a back up frame that contains cooling apparatus. The melting down of the metal happens in a very particular place in the foundry. When the mould is done and is ready to be cast, casters move the liquefied metal over large machines and equipment above the mould, this equipment helps the liquefied metal flow down into the cast. This equipment also monitors the rate at which the liquid metal flows into the cast. The cooling equipment then cools the metal down allowing the metal to harden and become a solid state. The castings are now removed and the product is now ready to be cleaned.

Metal casting isn’t the easiest process on the planet and problems can occur during the casting process. Pollution is a major problem worldwide, but in terms of metal casting, this can also have an effect on the metal. If the metal, in its liquid state is exposed to forms of pollution this will cause imperfections within the metal itself, thus when the metal is solidified it can cause weak spots and thus when the cast is removed from the mould, the cast can break. Not only can the casting become affected but the mould too. Gas bubbles can also form after the cooling process which will also cause the metal to become brittle and could possibly even show signs of bubbles on the metal itself. If there is malfunction or something goes wrong in the cooling process the cast could harden before all the metal fills the mould which will lead to deformations within the cast.

Some metal casting processes can be easily carried out by hobbyists and enthusiasts within their own chambers of work and don’t necessarily need to take place within a foundry.

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Unlimited Promotional Product Ideas With Die Casting

Die Casting for Promotional Products

Die Casting is a process where a mold is cut with the shape of the product you wish to produce. The mold consists of 2 halves. The one half forms the outside of the part, which you normally see, the show surface. This is called the cavity. The second half forms the inside of the part, the backside of the part. This is called the core. There is a gap between the cavity and the core that creates the part.

The mold can be produced in two different ways.

The first method is that a replicated model of the shape you want to mold is created. This shape is the same form as your finished product. This form is then used as a duplicator to cut metal away from a solid block to create each half of the mold. A separate model must be made for each half. The mold is then created in reverse to the part that is being produced.

The second method is that the mold halves are CNC cut using a CAD model. CNC stands for Computer Numerical Control and is used on automated machines to follow a pre-defined path to cut a shape. The CAD model can be produced in a few ways. CAD stands for Computer Aided Design.

One way to produce a CAD model is using 3D (3 dimensional) CAD software. A CAD Designer would design a virtual model of your part on the computer.

Another way would be to produce a part in CAD by using an actual sample of an existing part measured using a CMM and importing the data. CMM stands for coordinate measuring machine. These types of machines measure objects in 3D. The information that they generate can then be used in a CAD software program to construct a part.

3D Scanning can also be used for a process called Reverse Engineering. These scanners work with optics or lasers. They scan an actual part and produce an exact virtual replica within computer software. This CAD model can then be used to produce a mold.

Once the part is produced it can be painted, decals applied and assembled with other parts. Die cast parts are very durable. The are generally produced in aluminum or zinc. A big advantage of this method is that if you can think of a shape, you can make it.

here is my whole diecast model collection as of 1/8/11, i get my models from different places like dhsdiecast.com, evot-usa.com, or 3000toys.com

Why cast iron bench ends are perfect for you

What is one way to ensure that you don’t have the same product design as other people in your place? You either make sure that the product is produced at a limited stock, or you make your own. Some people resort to the latter for a number of reasons. Either they would like to personalize their product and let their creativity get the best of them or they would very much like an inexpensive alternative. Making your own product provides that opportunity.

Making your own bench is easy, if it is wooden. You just gather the necessary materials and tools, and download a free tutorial from the internet on how to make one and voila! You have your wooden bench. But what do you do for a cast iron bench? Unless you’re into molding and soldering yourself, cast iron bench ends are the answer to your solution.

Bench ends are the sides of benches and are sold in pairs. They are intricately designed sides, and once you purchase them, the only thing you have to do is make the body of the bench yourself. This is fairly easy, and you could use any material, but the most common is wood.

The following are some of the features of cast iron bench ends.

Diversity of designs

The malleability of cast irons allows it to be soldered and molded into almost any design. The cast iron bench ends have a number of designs that are attractive, authentic and unique. Whether the buyer is into contemporary or modern designs, traditional designs or unconventional designs, the cast iron bench ends have it all.

The material used

Cast iron is very durable and it can withstand harsh conditions. Be it rain, snow, hail, the sun or the mist, cast iron can easily weather that. Products made of this material can last a number of years and if given proper care, it could last a lifetime. Cast iron usually refers to grey iron, and has a low melting point and good fluidity. It has excellent resistance to deformation, and wear resistance. These make it an ideal material to be used in benches.

Cast iron bench ends can be found anywhere. They can be found in malls. They can be found in antiques shops and thrift shops. But instead of strolling around under the heat of the sun, you could easily contact your local furniture dealer and he/she can help you locate a pair. Another alternative would be the internet.

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Product Description
HELL’S FOUNDRY INC. SOFTDASH FLH 96-07 BK HFSD-58497-96MB

HELL’S FOUNDRY INC. SOFTDASH FLH 96-07 BK HFSD-58497-96MB

Product Description
At one time most towns of any size had somewhere a small foundry which would undertake small casting jobs, often more out of interest and good neighbourliness than for commercial gain. Those days are no more and model engineers in many areas must either adapt commerically available castings or send away to a specialist foundry which will undertake small work, often at some expense and with some delay. The alternative is to set up a home foundry and to make one’s own patterns and castings. This text covers all the basic principles of foundry work, describes materials and techniques, pattern-making, moulding boxes, cores and core-boxes, metals, all types of furnaces, and includes step-by-step procedures with examples of cylinders and wheels.

The Backyard Foundry

• Explore this unique game world and play strange races like the Iksar, Vah Shir and Froglok in EverQuest Classic
• EverQuest – The Ruins of Kunark draws players into a lush jungle continent rich with ancient artifacts, mysteries and creatures
• EverQuest – The Legacy of Ykesha is an exploration of desert wastes, where only nomads and supernatural beings live — and hide secrets
• EverQuest – The Shadows of Luclin takes you to an eerie moonscape as you explore another world — and face its dangers and challenges
• Game includes 30 days free game time

Product Description
An Online Role-Playing Experience!Product InformationExperience the fantasy world of role playing and embark upon adventures farabove your wildest dreams.  EverQuest and the lands of Norrath dare you toenter a living breathing world with thousands of other layers.  Chooseunique creatures ranging from classic Wood Elf Rangers to sinister Dark ElfNecromancers and develop your character with higher levels of power.  Writeyour own story in this epic role-playing game as you explore imaginary realmsbattle mystical creatures discover sacred treasures and formulate friendshipswith the most unlikely of creatures.Fantasy and adventure await!Product Features Create design and develop a truly distinctive character made just for you. Join players from across the world and form friendships in your adventure and quests. Prepare for battle with hundreds of weapons unique abilities magical spells and special skills. Journey across expansive continents filled with perilous dangers chilling monsters and beautiful landscapes beyond your imagination.Minimum Requirements 30 Day Subscription included for New Subscribers – Additional Online Fees Apply Thereafter  (Excludes SOE All Access Accounts) Internet Connection Required (Players are responsible for all applicable Internet Fees) A valid credit card or EverQuest Game Card required Windows 98SE Me 2000 XP Pentium III or greater processor 512 MB of RAM 1.5 GB Hard Drive space NVidia GeForce 3/ATI Radeon 8500 equivalent or greater (Direct #D cards not supported) DirectX compatible Sound Card DirectX 9.0 56K Internet connection 16X CD-ROM drive  

EverQuest: Chronicles Volume One

Product Description
A book that has a Complete Library of Jewelry Castings on Everything from Wedding Rings to Earrings and Everything else you can think of.

The Encylopedia of Jewelry Castings

Product Description
A book that has a Complete Library of Jewelry Castings on Everything from Wedding Rings to Earrings and Everything else you can think of.

The Encylopedia of Jewelry Castings

Product Description
At one time most towns of any size had somewhere a small foundry which would undertake small casting jobs, often more out of interest and good neighbourliness than for commercial gain. Those days are no more and model engineers in many areas must either adapt commerically available castings or send away to a specialist foundry which will undertake small work, often at some expense and with some delay. The alternative is to set up a home foundry and to make one’s own patterns and castings. This text covers all the basic principles of foundry work, describes materials and techniques, pattern-making, moulding boxes, cores and core-boxes, metals, all types of furnaces, and includes step-by-step procedures with examples of cylinders and wheels.

The Backyard Foundry

Product Description
3530 Bottle Jack 30 Ton AFF Bottle Jacks are built “forge-tough” in a wide selection of capacities for automotive, marine, construction, industrial and agricultural applications where the ability to lift, push, spread, bend, press and straighten either horizontally or vertically are essential. All have pistons for balance and easy positioning. Their saddles are made of machine-hardened steel and each is factory pre-tested at 150% of its rated capacity. AFF Bottle Jacks are also repairable for added value. All models with capacities of 8 tons or higher have convenient carrying handles while Model 3506C comes in a rugged plastic carrying case. To see the American Forge and Foundry Service and Warranty Page Click Here.

3530 Bottle Jack 30 Ton