Casting Metal is a manufacturing process where metal is melted at high temperatures and poured into a special mold. The metal cools and solidifies into the desired shape. The complexity and cost of casting molds vary widely, from inexpensive sand molds to precision-machined metal molds, which are suitable for mass production.It is commonly referred to as liquid metal forming or casting.
One major advantage of casting is its ability to produce parts that are close to their final shape, reducing the need for extensive machining after solidification. However, as metal shrinks during cooling, casting often results in rough surfaces and lower precision, which may require additional finishing processes.
Process flow: liquid metal → mold filling → solidification and shrinkage → casting.
Sand Casting
Different types of Metal Casting Process
- Sand Casting: Uses sand to create molds; low cost.
- Investment Casting: Wax models for detailed parts.
- Die Casting: Metal is injected into molds with pressure.
- Centrifugal Casting: Spins metal for hollow parts.
- Permanent Mold Casting: Reusable molds, long production.
- Shell Mold Casting: Thin molds, better surface finish.
- Vacuum Casting: Precision casting with less gas.
- Plaster Mold Casting: Plaster for fine details.
- Lost Foam Casting: Foam patterns for complex shapes.
- Continuous Casting: Metal flows continuously.
- Squeeze Casting: Combines casting and forging.
- Slush Casting: For hollow items.
- Graphite Mold Casting: Uses graphite molds.
- Pressure Casting: Gas pressure forces metal into molds.
These 14 types of casting methods can be classified as expendable molds (used once and destroyed) and non-expendable molds (reusable). Expendable mold casting uses materials like resin-bonded sand, ceramic shell, plaster, or foam. Common types include sand casting,lost wax casting, investment casting, Lost Foam Casting,Plaster Mold Casting and Shell Mold Casting. Non-expendable molds are made from durable materials like cast iron or steel, used in methods such as die casting and slush casting and so on.
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Forging
Forging is a metalworking process where heated solid metal is repeatedly deformed to change its shape and improve its internal structure. This process enhances the metal’s strength and hardness without negatively affecting its ductility. Forging is used in both low and high-volume production and produces some of the strongest metals used in industry today. The main goal of forging is to improve mechanical properties such as strength, hardness, and toughness by refining the grain structure.
Different types of Metal Forge
Forging is divided into several types to meet different material and manufacturing needs. Each type offers unique advantages. For example, Hot forging improves material ductility and is ideal for shaping tougher metals. Cold forging provides higher dimensional accuracy for softer metals like aluminum. Drop forging is used for high-strength parts due to its impact force, while Press Forging provides precise control with hydraulic pressure. Each method offers benefits in terms of efficiency, strength, and material properties, tailored to the production needs.
Metal Forging Process
- Metal Choice: Various metals like steel, aluminum, and copper can be forged, with heavier metals needing heat treatment.
- Shaping: Metal is heated, then shaped by hammering, pressing, or compressing.
- Hardening: Cold forging strengthens the metal during the process, while hot forging hardens through recrystallization.
- Tempering: The metal is heated, cooled, and reheated to reduce brittleness and improve toughness.
- Completion: Forging enhances strength and durability, making parts more resistant to wear and extreme conditions.
How to improve product after forging or casting
After forging or casting, several post-processing methods can be applied to improve product quality, accuracy, and performance. These include:
- CNC Machining: For precision shaping, drilling, or finishing.Casting or forging creates a near-net shape, reducing waste and lowering material costs.CNC ensures high accuracy and tight tolerances, refining the shape beyond what is achieved through forging or casting alone.It improves surface smoothness, removing any imperfections from the initial process.And CNC allows for the addition of intricate details and features that are difficult to achieve during forging or casting.
- Heat Treatment: Enhances strength, hardness, or ductility (e.g., tempering, annealing).
- Surface Treatments: Techniques like polishing, painting, or powder coating for aesthetics and corrosion resistance.
- Grinding: Ensures smooth surfaces or specific tolerances.
