Castings

Casting, like forging, has the ability to create finished product or near net shape parts which can be machined to the final dimensions. Using a cast part can limit waste, decrease machine time and increase the strength of a part which would traditionally be 100% machined.

Permanent Mold Casting

  • Low Pressure Die Casting
  • High Pressure Die Casting
  • Gravity Die Casting
  • Centrifugal Casting
  • Vacuum Casting

Special Processes

  • Continous Casting
  • Squeeze Casting
  • Chilled Casting



Permanent Pattern Casting

A permanent pattern in the shape of the finished product is either pressed into a median or the median is formed around the pattern. The pattern is removed and cores are placed into the mould, if necessary, prior to metal being poured into the formed cavities. After the metal has cooled the median will be broken and removed. Many materials, sizes and shapes can be used in the permanent pattern casting process. Medians/Processes
  • Sand Casting (Water & Clay Bond)
    • Green Sand
    • Skin Dry Sand
    • Dry Sand
    • Core Sand
    • Floor and Pit
    • Loam
    • High Pressure
  • Resin Bond
  • Plaster Bond
  • Silicate Bond
  • No Bond

Expendable Pattern (Investment)

Wax or foam is placed into permanent moulds which creates patterns of the finished product. The patterns are then placed on a sprue (also known as a tree) which is then dipped in a ceramic media, dried and heated to remove the wax or foam. The metal is poured into the ceramic pattern, cooled and broken apart to reveal the cast product. The final process is removing the individual parts from the tree. This process is used for relatively small detailed shapes. This process has the ability to create parts with thin walls and tight tolerances with little or no secondary machining necessary.
Medians
  • Investment - Lost Wax
  • Investment - Lost Foam

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Last Updated: October 2010