Expendable mold casting methods
- Expendable mold casting includes sand, plastic, shell, plaster, and investment (lost-wax technique) moldings.
- These methods use temporary, non-reusable molds.
- Widely used for casting complex shapes in industries such as automotive, aerospace, and medical devices.
- Offers cost-effective production of small to medium-sized batches.
Non-expendable mold casting methods
- Non-expendable mold casting does not require reforming the mold after each production cycle.
- Includes permanent, die, centrifugal, and continuous casting methods.
- Improves repeatability and delivers near net shape results.
Specific casting methods
- Sand casting is one of the most popular and simplest types of casting.
- Loam molding is used for producing large symmetrical objects like cannon and church bells.
- Plaster mold casting uses plaster of paris as a mold material.
- Shell molding provides a finer surface finish compared to sand casting.
- Investment casting, also known as lost-wax casting, is suitable for producing net shape components with high accuracy and repeatability.
- Casting is a solidification process that controls most properties of the casting.
- Casting defects, such as gas porosity and solidification shrinkage, occur during solidification.
- Cooling curves are important for controlling the quality of a casting.
- Chvorinov's rule calculates the local solidification time of a casting.
- The gating system conveys the liquid material to the mold and controls various factors.
- Shrinkage occurs during solidification and can be controlled through directional solidification, risers, and chills.
Macrostructure and casting process simulation
- The grain macrostructure in ingots and most castings have three distinct regions: the chill zone, columnar zone, and equiaxed zone.
- Casting process simulation uses numerical methods to calculate cast component quality, including mold filling, solidification, and cooling.
- Simulation accurately describes a cast component's quality before production starts, reducing the need for pre-production sampling.
Metal casting Data Sources