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Different Casting Methods for Making Auto Parts
2016-03-17

Precision Casting is a process that pour a liquid material into a mold containing a desired shaped hollow cavity, and then made to solidify. And then the ejection or breaking out of the casting takes place to get the process completed. Generally speaking, because other methods are not feasible, complex shaped components are usually made by casting. The history of casting can be traced back to 6000 years ago,and it has two distinctive subdivisions: non-expendable and expendable mold casting.

Moreover, non-expendable mold casting includes at least 4 distinct methods, called continuous, centrifugal, die and permanent casting.

Continuous casting: this method can be defined as a refined process of casting for high-volume, continuous production of metal sections with constant cross-section. In this method, the molten metal will be poured into a water-cooled, open-ended copper mold, which allows a layer of solid metal to be formed above the still-liquid center. Besides, aluminum, copper, and steel are common materials for continuously cast. And thanks to its cost effectiveness, it is widely accepted.

Centrifugal casting: because the force feed of this method is created by the way of using a temporary sand mold in spinning chamber as 900 N, it is an independent of both pressure and gravity. And the lead time is vary according to the application. True and semi-centrifugal processing allow 30 to 50 pieces per hour, while the batch processing has an upper limit of around 9000Kg. Generally, this method is used for casting jewelry, and it is also apply for railway wheels.

Die casting: it is regarded as a process of forcing molten metal into cavities pf mold under high pressure. These castings comprise of nonferrous metals, especially alloys of aluminum, copper, and zinc. And it is normally used in producing finer parts.

Permanent mold casting: this casting is made up of non-ferrous metals. It requires some time to set up, after which it can produce 5 to 50 pieces per hour. The coating of acetylene soot is applied to steel cavities, which helps in removing the work piece easily and promoting longer life. However, permanent molds possess a limited life span, replacement or refinishing is needed foe those worn molds.

Expendable mold casting can be referred to as a standard classification, and there are two methods of this casting.

Sand casting: it is one of the simplest and most popular casting types since ancient time. It involves very small size operations. The bonding of sand takes place by use of clays or polymerized oils or chemical binders.

Plaster casting: in fact, there is almost no difference between plaster casting and sand casting, except that plaster is used in place of sand. Similarly, there are also plastic and concrete castings.