Click to read the related article: What are the Top Ten Casting Processes You Know? (1)
V. Centrifugal Casting.
Centrifugal casting is a casting method in which molten metal is poured into a rotating mold and solidified under centrifugal force.
Advantages:
1. Almost no metal consumption in the gating and riser systems, improving the process yield;
2. No core is needed when producing hollow castings, thus greatly improving the metal filling capacity when producing long tubular castings;
3. High casting density, fewer defects such as porosity and inclusions, and high mechanical properties;
4. Easy to manufacture composite metal castings such as cylinders and sleeves.
Disadvantages:
1. Limited when used for producing irregularly shaped castings;
2. Inaccurate inner hole diameter, relatively rough inner hole surface, poor quality, and large machining allowance;
3. Castings are prone to specific gravity segregation. Applications: Centrifugal casting was first used in the production of cast pipes. Domestically and internationally, it is widely used in metallurgy, mining, transportation, irrigation and drainage machinery, aviation, defense, and automotive industries to produce steel, iron, and non-ferrous carbon alloy castings. It is particularly prevalent in the production of centrifugal cast iron pipes, internal combustion engine cylinder liners, and bushings.
VI. Metal Mold Casting.
Metal mold casting refers to a forming method in which molten metal is filled into a metal mold under gravity and then cooled and solidified within the mold to obtain a casting.
Advantages:
1. Metal molds have high thermal conductivity and heat capacity, resulting in rapid cooling, dense casting structure, and mechanical properties approximately 15% higher than sand casting.
2. It can obtain castings with high dimensional accuracy and low surface roughness values, and good quality stability.
3. Because sand cores are used little or no, it improves the environment, reduces dust and harmful gases, and lowers labor intensity.
Disadvantages:
1. Metal molds themselves are not permeable, requiring specific measures to remove air from the mold cavity and gases generated by the sand core;
2. Metal molds lack flexibility, making them prone to cracking during solidification;
3. Metal mold manufacturing has a long cycle time and high cost. Therefore, it only demonstrates good economic benefits in large-scale batch production.
Applications: Metal mold casting is suitable for mass production of complex-shaped non-ferrous alloy castings such as aluminum and magnesium alloys, as well as for producing castings and ingots of ferrous metals.
VII. Vacuum Die Casting.
Vacuum casting: An advanced die casting process that eliminates or significantly reduces porosity and dissolved gases in die castings by removing gas from the die casting mold cavity during the die casting process, thereby improving the mechanical properties and surface quality of the die castings.
Advantages:
1. Eliminates or reduces porosity inside die castings, improving mechanical properties and surface quality, and enhancing plating performance;
2. Reduces cavity back pressure, allowing the use of lower specific pressures and alloys with poorer casting properties, potentially enabling the die casting of larger parts with smaller machines;
3. Improves filling conditions, allowing for the die casting of thinner parts;
Disadvantages:
1. Complex mold sealing structure, difficult manufacturing and installation, resulting in higher costs;
2. Vacuum die casting's effectiveness is not significant if not properly controlled.
VIII. Extrusion Casting.
Extrusion casting: A method of solidifying and flowing liquid or semi-solid metal under high pressure to directly obtain parts or blanks. It has advantages such as high utilization of liquid metal, simplified processes, and stable quality, making it an energy-saving metal forming technology with potential applications.
Direct extrusion casting: Spraying coating, pouring alloy, mold closing, pressurizing, holding pressure, depressurizing, mold parting, blank demolding, and repositioning.
Indirect extrusion casting: Spraying coating, mold closing, feeding, mold filling, pressurizing, holding pressure, depressurizing, mold parting, blank demolding, and repositioning.
Technical characteristics:
1. Eliminates internal defects such as porosity, shrinkage cavities, and shrinkage porosity.
2. Low surface roughness and high dimensional accuracy.
3. Prevents casting cracks.
4. Facilitates mechanization and automation.
Applications: Can be used to produce various types of alloys, such as aluminum alloys, zinc alloys, copper alloys, and ductile iron.
IX. Lost foam casting.
Lost foam casting (also known as solid foam casting): A new casting method in which paraffin or foam models similar in size and shape to the casting are bonded together to form a model cluster, coated with refractory coating and dried, then buried in dry quartz sand and vibrated to create the model. Under negative pressure, the casting is poured, causing the model to vaporize, the liquid metal to occupy the model's position, and after solidification and cooling, the casting is formed. Process Flow: Pre-foaming → Foaming Molding → Coating Impregnation → Drying → Molding → Casting → Sand Removal → Cleaning.
Technical Features:
1. High casting precision, no sand core, reducing processing time;
2. No parting line, flexible design, high degree of freedom;
3. Clean production, no pollution;
4. Reduced investment and production costs.
Applications: Suitable for producing various sizes of relatively precise castings with complex structures, regardless of alloy type or production batch size. Examples include gray cast iron engine housings and high manganese steel bent pipes.
X. Continuous Casting.
Continuous casting: An advanced casting method. Its principle is to continuously pour molten metal into a special metal mold called a crystallizer. The solidified (shelled) casting is continuously pulled out from the other end of the crystallizer, allowing for castings of any length or a specific length.
Technical Features:
1. Rapid cooling of the metal results in dense crystallization, uniform structure, and good mechanical properties.
2. Saves metal and increases yield.
3. Simplifies processes, eliminating molding and other steps, thus reducing labor intensity and significantly reducing the required production area.
4. Continuous casting production is easily mechanized and automated, improving production efficiency.
Applications: Continuous casting can be used to cast long castings with unchanged cross-sectional shapes, such as ingots, slabs, bars, and tubes, from steel, iron, copper alloys, aluminum alloys, and magnesium alloys.
As a professional manufacturer of Stainless Steel Pump Casing, we are committed to providing customers with high-precision, high-strength Stainless Steel Pump Casing products, along with comprehensive technical support and solutions.
We firmly believe that the quality of our Stainless Steel Pump Casing and other castings is key to winning customer trust, while innovation and efficient service are the driving forces behind our continued development. Choose us, and you will receive high-quality cast Stainless Steel Pump Casing and attentive full-service support.
We are confident in recommending our Stainless Steel Pump Casing, impellers, and other products to you, and we are confident you will be satisfied. Our strong factory support can also meet your unique needs, enabling high-level customized production.