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Comprehensive analysis of the casting process, at a glance to identify the range of die-casting products

Views: 0     Author: Site Editor     Publish Time: 2025-02-05      Origin: Site

The liquid metal is poured into the cast type cavity suitable for the shape and size of the part, and then cooled and solidified to obtain the production method of blank or parts, usually known as metal liquid forming or casting.


process flow: liquid metals →Charge type→ solidifying contraction → foundry

Process features:

1, can make extremely complex shapes, especially good at dealing with complex components of the inner cavity.

2, highly adaptable, not limited by alloy type, a wide range of casting sizes.

3. Material access is convenient, the waste can be recycled and remelted, and the equipment investment cost is relatively low.

4, But the rejection rate is high, the surface quality needs to be improved, and the working environment conditions are poor.铸造分类

(1)sand casting

Sand casting: Sand casting is a method of producing castings in sand mold, suitable for the manufacture of steel, iron and most non-ferrous alloy castings.

Process flow:

Sand-type casting process flow

technical feature:

1, especially suitable for manufacturing complex shapes, especially the inner cavity structure of the blank;

2, a wide scope of application, and the cost is relatively low;

3, For some poor plastic materials, such as cast iron, sand casting is the only forming process, used for the manufacture of its parts or blanks.

Application: automobile engine cylinder block, cylinder head, crankshaft and other castings

(2) Melting casting (investmentcasting)



Melting casting: this usually refers to a casting scheme: first made with molten material, and then on the outer surface of the refractory to form a shell, and then melt and discharge the shell, in order to obtain a cast without classification surface. After high temperature roasting, the sand can be filled for pouring. Often referred to as "lost wax casting".

Process characteristics

Advantages: 1, with high size accuracy and geometric accuracy; 2, can cast a complex shape and alloy type of unlimited casting; 3, but the surface roughness is relatively high.

Disadvantages: complex process, high cost.

Application: Suitable for manufacturing small parts with complex shape, high accuracy or difficult to use other methods, such as turbine engine blades.

(3)die casting

Die casting: it uses high pressure to press the metal liquid into a precision metal mold cavity at high speed, and the metal liquid cools and solidifies under the pressure to form the casting.


Process characteristics

merit:

1. In the die casting process, the metal liquid bears high pressure and rapid flow rapidly.

2, excellent product quality, accurate size and stable, strong interchangeability.

3, high production efficiency, die-casting mold durable, high frequency of use.

4, very suitable for large-scale mass production, with remarkable economic benefits.

shortcoming:

1, the casting is easy to produce small pores and loose tissue.

2, the die casting plasticity is poor, should not withstand the impact load or work in the vibration environment.

3. High melting point alloy die casting will lead to the shortening of casting life and limit the expansion of die casting production.

Application: Die casting technology was initially applied in the automotive industry and instrument manufacturing, and then widely penetrated into agricultural machinery, machine tools, electronics, defense, computers, medical equipment, clocks, cameras and daily hardware and other fields.

(4)low pressure casting



Low pressure casting: it is a method for ordering liquid metal to fill under lower pressure (0.02~0.06MPa) and crystallize under pressure to form a casting.

process flow:

technical feature:

1. The pouring pressure and speed can be adjusted, suitable for a variety of castings (such as metal type, sand type) and alloy, can cast castof different sizes.

2. Using the bottom injection filling type, the metal liquid is stable without splashing, reducing the gas involvement and the erosion of the type wall, and improving the qualified rate of the casting.

3. Casting crystallizes under pressure, with dense tissue, clear outline, smooth surface, superior mechanical properties, especially suitable for large and thin wall casting.

4, no need to fill the mouth, metal utilization rate as high as 90~98%.

5, low labor intensity, good working conditions, simple equipment, easy to achieve mechanization and automation.

Application: Mainly used in traditional products, such as cylinder head, wheel hub, cylinder frame, etc.

(5)centrifugal casting



Centrifugal casting: it is a casting method of pouring metal liquid into the rotating casting type under the action of centrifugal force.

Process characteristics

merit:

1. Significantly reduce the metal consumption of the pouring system and the vent system, and improve the process production rate.

2, the production of hollow casting without type core, greatly enhance the metal filling capacity of long pipe casting.

3, casting to high density, defects such as pores, less slag, excellent mechanical properties.

4, easy to manufacture cylinder, sleeve type of composite metal castings.

shortcoming:

1. There are some limitations in the production of special castings.

2. The diameter accuracy of the casting is insufficient, the surface is rough, the quality is poor, and a large processing allowance is required.

3. Castings are prone to specific gravity segregation phenomenon.

apply:

Centrifugal casting technology was originally applied in casting pipe production, and has been widely used in metallurgy, mining, transportation, drainage machinery, aviation, national defense, automobile and other industries, for the manufacture of steel, iron and non-ferroic carbon alloy castings. Among them, the production of centrifugal cast iron pipe, inner combustion engine cylinder liner and shaft sleeve is particularly common.

(6)gravity die casting



Metal casting: a forming method for forming liquid metal by filling with metal casting by gravity and cooling and solidification in shape.

process flow:

Process characteristics

merit:

1. The metal type has high thermal conductivity and heat capacity, rapid cooling, close casting organization, and the mechanical properties are about 15% higher than that of the sand type casting.

2. It can produce castings with high dimensional accuracy and low surface roughness, and with stable quality.

3, reduce or without the use of sand core, is conducive to environmental protection, reduce dust and harmful gas emissions, reduce labor intensity.

shortcoming:

1. The metal type lacks air permeability, so measures need to be taken to derive the gas produced by the type cavity and sand core.

2, metal inelastic, casting solidification is easy to produce crack.

3, metal manufacturing cycle is long, high cost, only in the mass production can show good economic benefits.

Application: Metal casting is suitable for the mass production of aluminum alloy and magnesium alloy, and also for the production of steel casting and ingot.

(7)vacuumdie casting


Vacuum casting: This is an advanced die casting process, by extracting the gas in the mold cavity in the die casting process, effectively eliminate or reduce the pores and dissolved gas inside the die casting, so as to improve the mechanical properties and surface quality of the die casting.

process flow:

Process characteristics

merit:

1. Eliminate or reduce the internal air hole of the die casting, enhance the mechanical properties, improve the surface quality and coating effect.

2. Reduce the reverse pressure of the cavity, allow the use of low specific pressure and slightly poor performance alloy, and may use small equipment die casting large casting.

3. Optimize the filling conditions and die-cast thinner castings.

shortcoming:

1, the mold sealing structure is complex, the manufacturing and installation is difficult, so the cost is high;

  • If the vacuum die-casting method is improperly controlled, the effect is not very significant.

(8)squeezing die casting


Extrusion casting: This is a method of making liquid or semi-solid metals solidify and flow to shape under high pressure environment to make parts or blanks directly. Its advantages include high utilization rate of liquid metal, simplified process and stable quality, which is an energy-saving and promising metal forming technology with broad application prospects.

process flow:

Direct extrusion casting: spray coating, pouring alloy, mold, pressure, pressure protection, pressure relief, mold separation, blank release, reset;

Indirect extrusion casting: spray coating, mold, feeding, filling type, pressure, pressure protection, pressure relief, mold separation, blank mold, reset.

technical feature:

1, can effectively eliminate the internal stoma, shrinkage hole and loose defects.

2. High surface finish, accurate size.

3, can prevent the occurrence of casting cracks.

4, facilitate mechanization, automatic production.

Application: suitable for the production of aluminum alloy, zinc alloy, copper alloy, ductile iron and other alloys.

(9)Lost foam casting



Lost die casting (also known as solid casting): this is a new casting method: paraffin or foam models similar to the cast are combined into model clusters, coated with refractory coating and dried, and then buried in dry quartz sand vibration shape. When pouring in the negative pressure environment, the model is gasified, the liquid metal fills the model position, and the casting is formed after solidification and cooling.

Process flow: pre-foam foam forming immersion coating drying shape pouring sand cleaning

technical feature:

1. High casting precision, no need for sand core, which reduces the processing time.

2, no classification surface restrictions, flexible design.

3. The production process is clean and pollution-free.

4. Reduce the investment and production costs.

Application: suitable for the production of precision castings with complex structure and different sizes, not limited by alloy type and production batch, such as grey cast iron engine box, high manganese steel elbow, etc.

(10)continual casting


Continuous casting: this is an advanced casting technology, its principle is to continuously pour the molten metal into the special crystal metal type, after the metal solidification (shell), continuously pull out the casting from the other end of the crystal, so as to make arbitrary or specific length of casting.

process flow:

technical feature:

1. Because the metal is rapidly cooled, the crystal is dense, the tissue is uniform, and the mechanical properties are good;

2, save metal and improve the yield;

3. Simplified the process, eliminating modeling and other processes, thus reducing the labor intensity; the required production area is also greatly reduced;

4, continuous casting production is easy to realize mechanization and automation, improve production efficiency.

Application: the continuous casting method can cast steel, iron, copper alloy, aluminum alloy, magnesium alloy and other long castings with constant section shape, such as ingot, slab, rod blank, pipe, etc.


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