Metal Casting

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Metal Casting Process

Die casting is a widely used technology in the metal casting process, involving the injection of molten metal into steel molds under high pressure. These molds, also known as tools or dies, are custom-designed for each project and ensure precision and repeatability in every part or component produced. There are two primary types of die-casting machines: hot chamber machines, suitable for alloys with low melting temperatures such as zinc, and cold chamber machines, designed for alloys with high melting temperatures, specifically aluminum. In both machine types, the molten metal is injected into the dies, where it quickly cools and solidifies into the final component or part, known as the casting.

Precision Investment Casting

Another widely utilized technology is precision investment casting, which employs the lost wax casting process to produce near-net-shape parts. These metal parts often require minimal to no additional machining, thanks to the superior surface finish achievable through this method, surpassing most other casting processes. The inherent strength and durability of low-to-mid-production runs and prototype cast metal parts make them ideal for high-wear applications. We deliver high-quality investment cast parts that offer exceptional reliability and outstanding performance benefits.

Investment Cast Process

Pattern configuration, lost wax casting pattern is created by injecting molten wax into an alloy die. Single molds or tree — like accuracy investment casting molds can be created for a large-scale high-volume run. The metal casting outer shell is built up through dipping the tree — like construction into ceramic slurry and then immediately coated with sand several times drying between each coat building layers. Inner cavity of investment cast is then dewaxed using high pressure and steam to force the wax out of the cavities and leaves the hollow tree — like construction of ceramic shell. Ceramic cavity is heated and cured, to prevent heat shock or ceramic shell from cracking once the liquid metal is poured into the ceramic tree — like construction shell. After the cast metal has cooled enough to handle, ceramic shell is removed from the tree and its components or parts by using a high impulse vibratory shaking. The components or parts are secondary machined if necessary, depending on the expectations of the components or parts and customer requirements.