Casting is a manufacturing process by which a liquid material is poured into a mold or die (which contains a hollow cavity of the desired shape) and then is allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold-setting chemistry after mixing two or more components together. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.
Horizontal Centrifugal Casting
Vertical Centrifugal Casting
Centrifugal casting is a method where a permanent mold is rotated continuously about its axis at high speeds as the molten metal is poured. The molten metal is centrifugally thrown towards the inside mold wall, where it solidifies after cooling. The casting is usually a fine grained casting with a very fine grained outer diameter, owing to chilling against the mold surface. Impurities and inclusions are thrown to the surface of the inside diameter, which can be machined away.
Continuous casting, also called strand casting, is the process whereby molten metal is solidified into a “semi finished” “Billet, bloom, or slab for subsequent rolling in the finishing mills. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary molds to form ingots. Since then, “continuous casting” has evolved to achieve improved yield, quality, productivity and cost efficiency. It allows lower-cost production of metal sections with better quality, due to the inherently lower costs of continuous, standardized production of a product, as well as providing increased control over the process through automation.
Sand / Static / Pattern Casting
Sand casting also known as sand molded casting, is a metal casting process characterized by using “Sand” as the mold material. The term “sand casting” can also refer to an object produced via the sand casting process.
Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities gate system are created by compacting the sand around models, or patterns, or carved directly into the sand.
Pattern castings can also be made from Wood, Aluminum and Foam.