Casting Machines
Casting machines constitute the collection of equipment used to shape and form molten metal into various shapes and forms with the help of a die. This includes the furnaces, ladles, tundishes, impression devices, clamping units, dies, and gating systems that are found on most casting machines.[1]
Casting helps produce metal parts with arbitrary complex shapes, especially those with complex inner cavity shapes. The process imparts strong adaptability with the opportunity to create unlimited types of alloys, almost unlimited size of castings. Wide variety of source of materials can be used, the waste products can be remelted, and the equipment investment is relatively low in casting. Casting process also generates large amounts of scrap, surface quality achieved is generally low and working conditions are poor.[2]
Types of Casting Machines
Casting machines are broadly classified into the following based on the mechanism employed for casting the metal:
- Die casting machines: These utilize a pneumatic or hydraulic actuator and uses high pressure to press molten metal into a precision metal mold cavity at high speed. The molten metal is then cooled and solidified under pressure to form a casting.[1][2]
Pressure Die Casting (Source: Engineering Clicks) - Vacuum casting machines: This is an advanced die-casting method that improves the mechanical properties and surface quality of die-castings by eliminating or significantly reducing the pores and dissolved gases in the die-castings by pumping out the gas in the die-casting mold cavity.[2] These implement a vacuum to expulse air from the die chamber, draw the molten liquid into the cast, and hold sand in place as the molten material is poured.[1]
- Continuous casting machines: In this method, molten metal is continuously poured into a special metal mold called a crystallizer, and the solidified (crusted) casting is continuously poured from the other side of the crystallizer. It is then pulled out at one end to obtain castings of any length or a specific length.[2] They require a conveyor system as well as mechanical shears.[1]
- Centrifugal casting machines: It is a casting method in which molten metal is poured into a rotating mold, which gets filled and solidified under the action of centrifugal force.[2] They require a motor and shaft upon which the mold is affixed.[1]
- Sand Casting: It is a method in which castings are produced in sand molds, used to produce steel, iron and most non-ferrous alloy castings.[2]
Sand Casting (Source RapidDirect) - Investment Casting: This usually refers to making a pattern from a fusible material, coating several layers of refractory material on the surface of the pattern to make a shell, and then melting the pattern to discharge the shell, so as to obtain a mold without a parting surface, which is roasted at high temperature. The casting scheme that can be filled with sand after pouring. It is also often referred to as “lost wax casting”.[2]
- Low-pressure casting: This refers to the method of filling a mold with liquid metal under the action of low pressure (0.02-0.06MPa) and crystallizing under pressure to form castings.[2]
- Gravity Die Casting/Metal mold casting: In this method, liquid metal fills a metal mold under the action of gravity and cools and solidifies in the mold to obtain a casting.[2]
- Squeeze Die casting: It is a method of solidifying and flowing forming liquid or semi-solid metal under high pressure to directly obtain workpieces or blanks. It has the advantages of high utilization rate of liquid metal, simplified process and stable quality. It is an energy-saving metal forming technology with potential application prospects.[2]
- Lost foam casting/Solid casting.: it is to bond and combine paraffin or foam models similar in size and shape to the castings to form a model cluster. It is a new casting method that the mold is vaporized by pressing down and pouring, and the liquid metal occupies the position of the mold, solidifies and cools to form a casting.[2]
References
- ↑ 1.0 1.1 1.2 1.3 1.4 "Casting Machines Information". GlobalSpec. Retrieved 18 April 2024.
{{cite web}}: CS1 maint: url-status (link) - ↑ 2.00 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 IN3DTEC (2023-03-08). "10 different types of metal casting process". IN3DTEC | Prototyping & On-demand manufacturing services. Retrieved 2024-04-28.
