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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the pattern is withdrawn, its imprint provides the mold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.
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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.
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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.
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
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