Industrial Casting and Die Casting Manufacturers

Casting and Die Casting

Casting Casting is a manufacturing process in which molten metal is poured or injected and allowed to solidify in a suitably shaped mold cavity. During or after cooling, the cast part is removed from the mold and then processed for delivery. Industrial casting processes and cast-material technologies vary from simple to highly complex. Material and process selection depends on the part's complexity and function, the product's quality specifications, and the projected cost level.

Die Casting
Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts. It is accomplished by forcing molten metal under high pressure into reusable metal dies. The process is often described as the shortest distance between raw material and finished product. The term "die casting" is also used to describe the finished product.

Impregnation Casting
Impregnation of manufactured metal castings and powdered metal parts means sealing the leaks resulting from porosity. The impregnating material is introduced as a liquid into the voids, or porosity, within the wall of the part, typically using vacuum and pressure. The material is then solidified, filling the porous openings and making the part pressure tight.

Investment Casting
Investment casting or 'lost wax process' is an industrial process which employs in-process control at every point. Highly refined on-line process control methods are backed up with laboratory skill. Every casting manufactured and shipped--and this applies equally to orders for a dozen castings or half a million--can be relied on to meet the designer's performance specification. Investment castings are utilized today in virtually every industry where production quantities of metal parts are required. Furthermore, investment castings are now obtainable for prototype quantities of complex devices such as electronic housings, microwave components and subassemblies; without the necessity of producing the permanent dies to cast these devices.

Permanent Mold Casting
Permanent Mold castings are produced by forcing molten metal into a static mold consisting of a clamped metal assembly. Many industrial manufactured pressure-type castings, aircraft and missile castings, automotive pistons, pump bodies, and high-quality castings of any kind (even if the quantities required are small) are produced by the permanent-mold method. Advantages include: price, superior as-cast dimensional tolerance and surface finish, and improved mechanical properties compared to sand-casting. Although the initial cost of permanent molds is higher than that for sand casting pattern equipment, the lower cost of casting results in net savings over other casting methods.

Plaster Mold Casting
Plaster Mold casting employs molds formed with a gypsum-plaster base. It is a manufacturing process basically similar to sand casting in that the mold, usually made in two halves corresponding to the cope and drag of sand molding, is assembled for pouring of the mold. Plaster mold castings are best where the need for thin walls, accuracy, and good surface finish justifies their cost. Bladed, rotated castings such as pump and impeller parts, which do not usually lend themselves to die casting, are uniquely suitable for industrial plaster mold casting. Large numbers of electronic waveguide components have been cast in plaster because the accuracy and finish required on their internal surfaces are especially difficult to obtain by sheet metal forming, machining, or hand working.

Rubber Mold Casting
Rubber Mold (spin) casting is typically used for rapid prototyping of complex parts. A mold is prepared from uncured silicon rubber and then is cured in a heated vulcanizing press. The resulting mold is tough, resilient, dimensionally accurate, heat and chemically resistant. The mold is placed into a spin casting machine and liquid metal, plastic or wax is poured in. Pressure caused by centrifugal force pushes the liquid through the mold's runner system, completely filling every section, corner, detail and surface finish in each mold cavity. It is a precision casting process producing high integrity, close tolerance parts comparable to die casting or plastic injection manufacturing techniques.

Sand Casting
Sand Casting (also known as sand-mold casting) provides flexibility in shaping the manufactured part so that the imposed load is distributed evenly throughout for minimum stress concentration. When well-designed castings are used, stress concentrations can be reduced as much as 50%, and in many cases significant increases in industrial service life and strength can be achieved.

Aluminum Casting
Casting materials: aluminum, brass, lead, magnesium, zinc, ductile iron, electrolytic copper, ferrous, non-ferrous, graphite mold, gray iron, magnesium, malleable, stainless steel, steel, titanium, and zinc.
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		Casting is a manufacturing process in which molten metal is poured or injected and allowed to solidify in a suitably shaped mold cavity. During or after cooling, the cast part is removed from the mold and then processed for delivery. Industrial casting processes and cast-material technologies vary from simple to highly complex. Material and process selection depends on the part's complexity and function, the product's quality specifications, and the projected cost level.
		Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts. It is accomplished by forcing molten metal under high pressure into reusable metal dies. The process is often described as the shortest distance between raw material and finished product. The term "die casting" is also used to describe the finished product.
		Impregnation of manufactured metal castings and powdered metal parts means sealing the leaks resulting from porosity. The impregnating material is introduced as a liquid into the voids, or porosity, within the wall of the part, typically using vacuum and pressure. The material is then solidified, filling the porous openings and making the part pressure tight.
		Investment casting or 'lost wax process' is an industrial process which employs in-process control at every point. Highly refined on-line process control methods are backed up with laboratory skill. Every casting manufactured and shipped--and this applies equally to orders for a dozen castings or half a million--can be relied on to meet the designer's performance specification. Investment castings are utilized today in virtually every industry where production quantities of metal parts are required. Furthermore, investment castings are now obtainable for prototype quantities of complex devices such as electronic housings, microwave components and subassemblies; without the necessity of producing the permanent dies to cast these devices.
		Permanent Mold castings are produced by forcing molten metal into a static mold consisting of a clamped metal assembly. Many industrial manufactured pressure-type castings, aircraft and missile castings, automotive pistons, pump bodies, and high-quality castings of any kind (even if the quantities required are small) are produced by the permanent-mold method. Advantages include: price, superior as-cast dimensional tolerance and surface finish, and improved mechanical properties compared to sand-casting. Although the initial cost of permanent molds is higher than that for sand casting pattern equipment, the lower cost of casting results in net savings over other casting methods.
		Plaster Mold casting employs molds formed with a gypsum-plaster base. It is a manufacturing process basically similar to sand casting in that the mold, usually made in two halves corresponding to the cope and drag of sand molding, is assembled for pouring of the mold. Plaster mold castings are best where the need for thin walls, accuracy, and good surface finish justifies their cost. Bladed, rotated castings such as pump and impeller parts, which do not usually lend themselves to die casting, are uniquely suitable for industrial plaster mold casting. Large numbers of electronic waveguide components have been cast in plaster because the accuracy and finish required on their internal surfaces are especially difficult to obtain by sheet metal forming, machining, or hand working.
		Rubber Mold (spin) casting is typically used for rapid prototyping of complex parts. A mold is prepared from uncured silicon rubber and then is cured in a heated vulcanizing press. The resulting mold is tough, resilient, dimensionally accurate, heat and chemically resistant. The mold is placed into a spin casting machine and liquid metal, plastic or wax is poured in. Pressure caused by centrifugal force pushes the liquid through the mold's runner system, completely filling every section, corner, detail and surface finish in each mold cavity. It is a precision casting process producing high integrity, close tolerance parts comparable to die casting or plastic injection manufacturing techniques.
		Sand Casting (also known as sand-mold casting) provides flexibility in shaping the manufactured part so that the imposed load is distributed evenly throughout for minimum stress concentration. When well-designed castings are used, stress concentrations can be reduced as much as 50%, and in many cases significant increases in industrial service life and strength can be achieved.
		Casting materials: aluminum, brass, lead, magnesium, zinc, ductile iron, electrolytic copper, ferrous, non-ferrous, graphite mold, gray iron, magnesium, malleable, stainless steel, steel, titanium, and zinc. Brought to you by: