Conventional Die Casting

Metal object obtained by allowing molten metal to solidify in a mold, the shape being determined by the shape of the mold.

Certain advantages are inherent in the metal casting process. These often form the basis for choosing casting over other shaping processes such as machining, forging, welding, stamping, rolling, extruding, etc. it is also true that conditions may exist where the casting process must give way to other methods of manufacture, when other processes may be more efficient. For example, machining procedures smooth surfaces and dimensional accuracy not obtainable in any other way; forging aids in developing the ultimate of fiber strength and toughness in steel; welding provides a convenient method of joining or fabricating wrought or cast products into more complex structures; and stamping produces lightweight sheet metal parts.


Molding

The mold is made by packing some readily formed aggregate material, such as molding sand, around the pattern. When the pattern is withdrawn, its imprint provides the mold cavity, which is ultimately filled with metal to become the casting.

Molding usually involves placing a molding aggregate around a pattern held with a supporting frame, withdrawing the pattern to leave the mold cavity, setting the cores in the mold cavity and finishing and closing the mold.Cleaning refers to all operations necessary to the removal of sand, scale, and excess metal from the casting. The casting is separated from the mold and transported to the cleaning department. Burned-on sand and scale are removed to improved the surface appearance of the casting. Excess metal, in the form of fins, wires, parting line fins, and gates, is removed. Castings may be upgraded by welding or other procedures. Inspection of the casting for defects and general quality is performed.

Melting and Pouring

Cleaning refers to all operations necessary to the removal of sand, scale, and excess metal from the casting. The casting is separated from the mold and transported to the cleaning department. Burned-on sand and scale are removed to improved the surface appearance of the casting. Excess metal, in the form of fins, wires, parting line fins, and gates, is removed. Castings may be upgraded by welding or other procedures. Inspection of the casting for defects and general quality is performed.


Cleaning

All that is necessary to the removal of sand, scale, and excess metal from the casting. The casting is separated from the mold and transported to the cleaning department. Burned-on sand and scale are removed to improved the surface appearance of the casting. Excess metal, in the form of fins, wires, parting line fins, and gates, is removed. Castings may be upgraded by welding or other procedures. Inspection of the casting for defects and general quality is performed.

Additional processing

Prior to shipment, further processing such as heat-treatment, surface treatment, additional inspection, or machining may be performed as required by the customer's specifications.

Permanent mold castings, while not as flexible as sand castings in allowing the use of different patterns (different part designs), lower the cost of producing a part. At a production run of 1000 or more parts, permanent mold castings produce a lower piece cost part. Of course, the break-even point depends on the complexity of the part. More complex parts being favored by the use of permanent molds.

Instead of using sand as the mold material, a metal is used as a mold.

Other Permanent Mold Castings:

*Slush Casting
*Corthias Casting
*Low Pressure Permanent Mold Casting
*Vacuum Permanent Mold Casting


Industries of the Future approach advancing state-of-the-art in lost foam casting processs

The DOE Office of Industrial Technologies, working with the Lost Foam Casting Consortium, has aggressively pursued development and demonstration of an advanced casting technology termed "lost foam." Lost foam casting is a highly flexible casting process that allows complex metal components to be cast into final or near-final form, reducing waste and additional energy expenditures incurred by the extensive milling process required in conventional casting. The success of the lost foam research project exemplifies the benefits of industry-government partnerships at work. Industry and government are working together to achieve goals in energy and economic competitiveness. A new generation of students is being trained in the latest casting technologies.

See Predicting defects in Lost Foam Casting

Lost Foam Casting Consortium: Advanced Cast Products, Inc.; Ashland Chemical Co.; Austin Associates; BMW AG; Borden, Inc.; Bradken Marion Corp.; Caterpiller, Inc.; Carbo Ceramics; Citation Corp.; Copeland Corp.; Foseco-Morval Inc.; General Kinematics Corp.; General Motors; J.S. McCormick; Kohler Company; Lost Foam Technologies; Matrix Technologies; Mercury Marine; Mueller Corp.; Nemark; Saturn Corp.; Stanton PLC; Styrochem International; Tecpro Corp.; Maco Corp.; UES Inc.; Vulcan Engineering; Willard Industries

Wax Casting - INVESTMENT CASTING

Forging - Processes