Details of the Casting Producing for the Goods

 

  Many of the clients think the cheaper producing is from the casting, but is not correct 100%. Below are the details to make the clear introduction from our Shenzhen Xinyeda Precision Co., Ltd.

 

  Casting is a manufacturing process in which molten metal is poured into a mold cavity and solidifies into a shaped part. Based on mold material, forming method, and process characteristics, casting processes are mainly classified as follows:

 

 

  Characteristics: The most traditional and widely used process; molds are made of molding sand.

 

  Advantages: Low cost, no limitation on part size or shape, suitable for both single-piece and mass production.

 

  Disadvantages: High surface roughness, low dimensional accuracy, large machining allowance.

 

  Applications: Cast iron, cast steel, non-ferrous metals; machine tool beds, engine blocks, valve bodies, etc.

 

 

  Characteristics: Uses reusable metal molds (hard-mold casting).

 

  Advantages: Good surface quality, high dimensional accuracy, fine grain structure, high production efficiency.

 

  Disadvantages: High mold cost, not suitable for high-melting-point metals, limited for complex geometries.

 

  Applications: Low-melting-point alloys such as aluminum, magnesium, and zinc in small-to-medium batch production.

 

 

 

  Characteristics: Molten metal is injected into a metal mold cavity at high pressure and high speed, solidifying under pressure.

 

  Advantages: Extremely high precision (IT11–IT13), excellent surface finish, capable of producing thin-walled complex parts, very high production rate.

 

  Disadvantages: Very high tooling cost, prone to porosity, cannot be strengthened by heat treatment.

 

  Applications: High-volume production of aluminum, zinc, and magnesium alloys; automotive housings, smartphone mid-frames, motor enclosures.

 

  压铸产品图片

 

  Characteristics: Molten metal is pushed upward into the cavity under relatively low pressure (0.02–0.08 MPa).

 

  Advantages: Smooth mold filling, minimal oxide inclusions, dense microstructure, high yield rate.

 

  Disadvantages: Lower production efficiency than die casting.

 

  Applications: Aluminum alloy wheels, cylinder heads, pressure-resistant housings.

 

  Characteristics: A wax pattern is coated with multiple layers of refractory material → dewaxed → baked → poured.

 

  Advantages: Exceptionally high precision (IT5–IT8), low surface roughness, capable of highly complex shapes, virtually no material limitations.

 

  Disadvantages: Many process steps, long lead time, high cost, limited part size.

 

  Applications: Precision parts in stainless steel, superalloys, and titanium; aerospace blades, medical devices, art castings.

 

 

  Characteristics: A foam polystyrene pattern is buried in dry sand; the foam vaporizes when molten metal is poured.

 

  Advantages: No parting line, no core required, high design freedom, simple cleaning.

 

  Disadvantages: Foam may cause carbon defects, moderate tooling cost.

 

  Applications: Complex box-shaped castings in cast iron and cast steel.

 

  Characteristics: The mold rotates, and molten metal fills and solidifies under centrifugal force.

 

  Advantages: Dense structure, free of porosity and shrinkage, hollow cylindrical parts can be made without a core.

 

  Disadvantages: Poor inner-diameter accuracy, inner wall prone to segregation.

 

  Applications: Cylinder liners, bushings, pipes, gear rings and other rotational parts.

 

  离型铸造图片

 

  Characteristics: Molten metal is continuously poured into a crystallizer, and solidified billets are drawn out continuously.

 

  Advantages: Extremely high efficiency, high material utilization, uniform microstructure.

 

  Disadvantages: Only suitable for simple cross-sections (square, round, slab).

 

  Applications: Steel billets, aluminum bars, copper tubes and other semi-finished products in the metallurgical industry.

 

 

 

  Characteristics: Mold is formed by pouring ceramic slurry.

 

  Advantages: Excellent surface finish, good dimensional accuracy, can produce large parts.

 

  Disadvantages: High cost, long production cycle.

 

  Applications: Large precision castings, mold cavities, rolling rolls.

 

 

  Characteristics: Plaster is used as the mold material.

 

  Advantages: Extremely smooth surface, excellent replication detail.

 

  Disadvantages: Low strength, only suitable for low-melting-point alloys.

 

  Applications: Decorative and art castings in aluminum, zinc, and copper alloys.