CNC Information

Art Casting Information

Metal Art Casting Information and stats on the various types of Artistic Casting can now be found at a new section on Metal Casting website that is all about Metal Art Casting. The new Metal Art Casting section can be accessed by users and non-users by visiting the following web address: Art Casting

Here is an excerpt from the Art Casting section page on Metal Casting Zone:

“Art casting is one form of excellence, put with diverse craft skills. It should be perfect and graceful at the same time. One should have unique craft skills which can produce a perfect art casting. There are several websites which can provide a person with information on art casting technique, their sculptors and the craft skills which are required to be a sculptor.

The websites that showcases the Art founders combines to provide advanced foundry techniques and similar superb craft skills. One can thus understand the sculptor’s needs and vision after viewing the art form. Previously, such sculptors were used in museums, galleries and exhibitions. Even today, at large the sculptors are used in public places, galleries and such art casting are made out of modern equipments and casting techniques.”

The new Art Casting webpage is there to provide users with all of the information they need on Artistic Metal Casting and learning the basics of Metal Art Casting. It can be visited for free at: Art Casting This new section of Metal Casting information will continue to be updated with the latest and greatest information on the basics of Art Casting at: Casting

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Cupola Casting Information along with Cupola Foundry Information Just Released

Cupola Casting Information and stats on the various types of Cupola Furnaces and Cupola Foundry’s can now be found at a new section on Metal Casting website that is all about Cupola Casting. The new Cupola Casting section can be accessed by users and non-users by visiting the following web address: Cupola Furnace

Here is an excerpt from the Cupola Casting section page on Metal Casting Zone:

“A Cupola is a type of furnace that is very much alike to blast furnace. The Cupola furnace is refractory lined, stack of steel that is around 20 to 35 feet high. It rests on a base plate that is made of cast iron and has four legs. The casting that is obtained from the cupola furnace is known as a cupola casting.

Cupola Furnace: The Cupola furnace is one of the oldest forms of furnace that have been used by the iron and metal foundries. The Cupola furnace is the crudest and the simplest furnace that has been used by the industries. However, the cupola’s use is declining and the furnace is fast being extinct.”

The new Cupola Casting webpage is there to provide users with all of the information they need on Cupola Casting and learning the basics of Cupola Foundry’s. It can be visited for free at: Cupola Casting. This new section of Cupola Casting information will continue to be updated with the latest and greatest information on the basics of Cupolas at:  Casting Furnace

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Backyard Foundry and DIY Home Foundry Information Just Released

Backyard Foundry Information and stats on the various types of Home Metal Casting Foundry’s can now be found at a new section on Metal Casting website that is all about DIY Metal Casting. The new Backyard Foundry section can be accessed by users and non-users by visiting the following web address: Backyard Foundry

Here is an excerpt from the Backyard Foundry section page on Metal Casting Zone:

“People who like to make their own artifacts and are enchanted with the idea of building new and useful things from scratch are sure to enjoy ‘do it yourself casting’ that can be done at home using simple methods and techniques. Many amazing things can be produced and created using you home made metal foundry. A good understanding of some basic foundry knowledge and few simple tools can help you make metal casting at home possible. Many people find it difficult to get special parts for their cars or bikes or even find it very costly to modify their cars, house or even bikes. If you develop your hobby of metal casting, then you can easily make special parts for your cars and bikes and also will find it easy and save a lot of money. Casting can be used to make many things like, simple ornaments knobs and even handles.”

The new Backyard Foundry webpage is there to provide users with all of the information they need on DIY Metal Casting and learning the basics of Metal Casting. It can be visited for free at: Home FoundryThis new section of Home Foundry information will continue to be updated with the latest and greatest information on the basics of DIY Metal Casting at: Backyard Foundry

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Metal Casting Information and Basic Metal Casting Information Released

Metal Casting Zone has just released a new section of their website that has all of the basics on Casting, Metal Casting, and Die Casting. This is part of a new community website that is all about Casting. Members and non-members can visit this Casting page on the Metal Casting website for free at: Metal Casting

Here is an excerpt from the new Metal Casting information webpage:

 “Casting can be defined as a process of manufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’ containing a desired shaped hollow cavity, and then made to solidify. The ejection or breaking out of the casting then takes place to get the process completed. The use of casting is ‘forming hot liquid metals’ or numerous metals that are cooled after having the components like clay, plaster, concrete, and epoxies mixed. Complex shapes are normally made by casting, as other methods are not feasible. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting. ‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.  Continuous casting: Continuous casting can be defined as a refined process of casting for high-volume, continuous production of ‘metal sections’ with constant cross-section. The pouring of molten metal into a water-cooled, open-ended copper mold takes place. This allows a ‘layer’ of ‘solid metal’ to be formed above the ‘still-liquid’ center. Continuous casting is widely accepted due to its cost-effectiveness. The metals continuously cast are aluminum, copper, and steel.” There is plenty of more information on the new general information metal casting website that can be found by visiting: Casting. There is also a special going on now that allows members to gain access to free ebooks and other free materials just for signing up as a member of the casting website for free at: Die Casting. Users should check back often to the metal casting general page as more information will be added as the website expands and grows. About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Electric Arc Furnace, Blast Furnace, and other Metal Casting Furnaces Just Released

Learn Metal Casting Processes and Metal Casting Techniques Just Released

Learn Casting and all about Metal Casting, and Casting at a new section on Metal Casting website that is all about Learn Casting. The new Learn Casting section can be accessed by users and non-users by visiting the following web address: Metal Casting

Here is an excerpt from the Learn Casting section page on Metal Casting Zone:

“There are various casting processes being implemented now days. The oldest amongst them is sand casting. Spin casting is also widely used. They can be described as follows:

Sand Casting: Sand casting involves formation of mold from a mixture of sand and to pour a casting liquid, most probably, a molten metal into mold. The metal is then allowed to solidify and the removal of mold, takes place. Sand molding consists of two types: green sand method and air set method. The first one consists of mixture of clay, moisture, silica, and many other additives. The second one consists of mixture of dry sand and other materials, not moist clay. They are mixed with the help of a quick curing adhesive. The collective use of these materials is called ‘air set’.

At times, there is temporary plug placed to pour the fluid which is to be molded. Air-set molds usually form molds consisting of two parts-the bottom and the top. The mixture of sand gets tamped down after its addition. It does not generate any by-product. After the solidification and cooling of metal, the mold gets usually destroyed. This is because its removal involves a lot of breaking and cracking. The casting accuracy depends a great deal on the sand and the process of molding used. Castings composed of green sand result into formation of rough texture on casting surface, and this characteristic makes them easily recognizable. Air-set molds produce smoother castings.”

The new Learn Casting webpage is there to provide users with all of the information they need on casting and learning the basics of metal casting. It can be visited for free at: Learn Casting .This new section of learn casting information will continue to be updated with the latest and greatest information on the basics of casting at: Learn Casting

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Casting Process and How to Preform the Casting Process

There are various Casting Process being implemented now days. The oldest amongst them is sand casting. Casting Process  is also widely used. They can be described as follows:

Sand Casting: Sand casting involves formation of mold from a mixture of sand and to pour a casting liquid, most probably, a molten metal into mold. The metal is then allowed to solidify and the removal of mold, takes place. Sand molding consists of two types: green sand method and air set method. The first one consists of mixture of clay, moisture, silica, and many other additives. The second one consists of mixture of dry sand and other materials, not moist clay. They are mixed with the help of a quick curing adhesive. The collective use of these materials is called ‘air set’.

At times, there is temporary plug placed to pour the fluid which is to be molded. Air-set molds usually form molds consisting of two parts-the bottom and the top. The mixture of sand gets tamped down after its addition. It does not generate any by-product. After the solidification and cooling of metal, the mold gets usually destroyed. This is because its removal involves a lot of breaking and cracking. The casting accuracy depends a great deal on the sand and the process of molding used. Castings composed of green sand result into formation of rough texture on casting surface, and this characteristic makes them easily recognizable. Air-set molds produce smoother castings.

Many a times, the Casting Process results in losing of components of sand mixture. It is possible to reuse green sand by the way of adjusting the composition to get the lost additives and moisture replenished. The entire pattern itself is eligible to be reused for producing novel sand molds. The method of reuse can be continued for an indefinite period. In 1950, casting process got automated partially. They have been in great demand for developing production lines since then. 

Spin Casting: Spin Casting is better known as Centrifugal Rubber Mold Casting (CRMC). It implies utilization of centrifugal force for producing castings out of rubber mold. As a customary practice, a mold having shape of a disc gets spun through its ‘central axis’ at a pre-decided speed. The material used for casting is usually thermoset plastic in the liquid form or a molten metal. It gets poured into the mold through the opening at its centre. Corresponding to the solidification of metal, or the setting of thermoset plastic, the spinning of the filled mold takes place.

Normally, organic rubber or vulcanized silicone is used as a mold-making substrate in spin casting. Vulcanization takes place in the middle of process of mold-making. After the successful completion of vulcanization process, venting and gating must be undergone by the mold. This implies carving of channels for ensuring proper material flow and air during the course of casting. A scalpel or knife is used to carry out the above two processes. The mold complexity is directly proportional to the time required in implementation of venting and gating.  

Iron Scraps Info and Iron Scraps Process Information

Iron Scraps can be referred to as products made out of melted iron molecules. These molecules are, first, poured into mold and allowed to cool. They are then extracted. The Iron Scraps properties depend a great deal on the foundry practice. They also depend on the cooling rate. Iron contains huge carbon concentrations. This content facilitates melting, simplicity of casting, and machining. Iron casting designs have a great variation owing to the property of iron to resist shrinkage during the process of cooling. The end product attains a great reputation for its strength and durability. Tensile strength ranges between 20,000 psi and over 60,000 psi. The values of hardness (without heat treatment) range between 100 and 300 BHN.

Some factors need to be considered while buying iron scraps. The first thing on the agenda should be, checking the quality of foundry used in products and procedures. This should be done because foundry practices determine the casting properties. The consumer might have a tough time in finding the apt one. Secondly, the concentration of carbon should be looked into. The percentage of carbon commonly ranges between 2.5 and 4%. An addition of even 0.1% would cause the tensile strength to decrease by around 2700 psi. Casting procedures differ from foundry to foundry.

Green sand molding is the most commonly used type of casting. Normally, small and medium sized products are produced using this type of casting. Shell molding is preferred for bigger applications. Shell molding facilitates cooling of the mold containing heated metal. This process gives a better finishing to the final product as compared to all the other processes. Centrifugal casting is used for producing big cylinders and pipes. Both, producer and consumer would get highly satisfied if a proper blend of correct casting process and reputed foundry is made.

Iron Scraps are utilized extensively in machinery, automotive, and agricultural industry. Parts such as turbine and pump housings, dynamometer bases, compressors are made out of iron castings. Majority of manufacturers have the caliber to go for high and low production outputs. They are also entitled to go for short order runs. There are standard prototypes ensuring customer satisfaction and accuracy. Some manufacturers provide finishing services like galvanizing, painting, and machining as well. In general, iron castings include alloy casting, ductile castings, and malleable castings. There are some terms relating to iron castings. They need to be known in order to get a fair idea of iron.

Brinell Hardness Number (BHN): It can be defined as the method used for measuring the hardness of iron. For %LINK2%, a metal ball of 3000Kg is put on a flat iron piece. After the removal of ball, indentation observed is recorded. This measurement indicates the value of hardness.

Tensile Strength: Tensile strength can be defined as the quantity of bending and stretching undergone by a material before tearing or breaking. Here the metal is iron.

Modulus of Elasticity: It can be defined as the ratio of stress to strain. This value determines the elasticity as well as the stiffness of the concerned material. 
 

Lost Wax Casting

Metal Casting Zone has just released a new Forum section of their website that has all of the informative questions and answers on Lost Wax Casting, Casting Wax, and other Lost Wax Casting Information. This is part of a new forum on the metal casting community website that is all about Casting. Members and non-members can visit this Forum page on the Metal Casting website for free at: Lost Wax Casting.

Here is an excerpt from the new Metal Casting Forum Lost Wax Casting information webpage:

“Lost Wax Casting is an ancient technique that has been used to create very complicated metal castings and involved pieces that would other wise be impossible either because of economic reasons or manufacturing reasons. Everyone from small jewelers to large industrial foundries can use Lost Wax Casting. This process is also called Investment Casting when it is used in commercial industries. While jewelry makers are the primary ones to use the Lost Wax Casting, many others use it to achieve a number aims and goals.

Lost Wax Casting is the ideal and preferred method for artists who are interested in making items like sculptures or rings from a variety of alloys like bronze, steel, or copper.

Die Casting

Die Casting Information and all about Low Pressure Die Casting and DieCasting Machines at new section on Metal Casting website that is all about Die Casting The new Die Casting section can be accessed by users and non-users by visiting the following web address: Die Casting.

Here is an excerpt from the Die Casting section page on Metal Casting Zone:

“Die casting is the method used for forcing molten metal into mold cavities under high pressure. Die casting is very versatile and hence, is the widest used method for casting a metal. Die casting is same as permanent mold casting the only difference is that the metal is injected into the mould at very high pressure of 10-210 Mpa. This results in a more uniform part, usually good dimensional accuracy and also good surface finish.

The different metals and alloys that can be used in die casting are zinc, aluminum, copper, magnesium, tin and lead. Ferrous metals can also be used for die casting, die casting method is generally used for applications in which a large quantity is medium or small sized parts are required with detail, good dimension and fine surface finish.

There are namely two equipments used for die casting cold chamber and hot chamber process.”

 

Gravity Die Casting

Gravity Casting Information and all about Gravity Die Casting and Gravity Casting at new section on Metal Casting website that is all about Gravity Casting The new Gravity Die Casting section can be accessed by users and non-users by visiting the following web address: http://www.metalcastingzone.com/gravity-casting/.

Here is an excerpt from the Gravity Casting section page on Metal Casting Zone:

“Gravity casting is done in ceramic molds, sand, permanent casting and also in investment or lost wax casting. The gravity casting process was started with common steel after successful implementation it was further tried on heat resistance super alloys. With recent development and with more refined methods today even titanium alloys are being cast using the gravity casting method and using ceramic crucibles. The use of desired mold designs and also specially made unique designs enable a reduction in the metal cast to yield the given part. This also helps in reducing the amount of energy that is used in making such casting articles.

With new developments, today even computerized control of the vacuum pressure and rate is possible. This enables the user to control the filling rate. This makes casting of high quality metals like and viscous metals like metal matrix and composites of aluminum casting possible.

Jewelry Casting Information

Jewelry Casting Information and all about Making Jewelry, and Casting Jewelry at new section on Metal Casting website that is all about Casting Jewelry. The new Jewelry Casting section can be accessed by users and non-users by visiting the following web address: Jewelry Casting.

Here is an excerpt from the Jewelry Casting section page on Metal Casting Zone:

“Casting Jewelry is very attractive and delicate. They are made using machines, but very finely crafted and hand made jewelry is also available in the market. This type of jewelry can be available at a very low, as well as high costs, depending on the design and material and design that you choose. Casting Jewelry is very fragile and should be handled with out most care as it can break easily. With the advent of casting jewelry, the fashion world has benefited a great deal. Today, free flowing designs, multicolored jewelry and even a special made to order jewelry is available in the market.

Before this, it was difficult to cast a metal in a desired shape but today it is as simple as it gets, all you need is a creative mind to create new designs and a group of well qualified workers and good machinery to make your own casting jewelry. This also gives you an option to make your own series of new designs. Casting jewelry is being widely used across the globe. With the prices of gold increasing day by day and with the entry of new metal jewelry like platinum, casting jewelry slowly but surely is making a mark in the fashion world. With the cost silver plated casting jewelry, the dream of wearing a new necklace or a new ear-ring everyday is a reality. You can actually afford new set of jewelry everyday. There are also costly models made of pure gold and delicate designs and with embedded diamonds that are available.”
 

3DP and Prototyping Technologies

Rapid prototyping is a process by which a working model or prototype is developed to test the various design ideas, features, concepts, use, functionality and performance. The user can immediately give a feedback to the producer. The technology of rapid prototyping is quite revolutionary and innovative and has found widespread applications in nearly all types of industries. The prototypes can be developed on the basis of past design and its performance and necessary modifications can be made to refine the final product as per the requirements. Rapid prototyping has manifold advantages like reduction of process cost, time and risks, conceptualizing of the actual product, delivery of high quality product, better communications and so on.

As it is with all the technologies, there are some disadvantages as well associated with rapid prototyping like communication gaps, high expectations of the users which are not fulfilled and so on. However, the benefits surely do override all the advantages. There are a host of different rapid prototyping technologies.

Rapid Prototyping Technologies: The numerous rapid prototyping technologies may include the various types like additive, formative or subtractive. Initially, rapid prototyping technologies involved only additive processes. The major difference between the various additive technologies is the method in which layers are built for creating parts. Some rapid prototyping technologies melt or soften materials for producing the Layers (FDM, SLS), whereas other technologies lay down liquid material called thermosets and these are later cured by different methods.

Prototyping Advantages

Rapid prototyping is a process of software development wherein physical objects are automatically constructed by means of SFF or solid freeform fabrication. In the process of rapid prototyping, a prototype or working model can be constructed quickly, and tested for its functionality, performance and output. The new features or ideas can be illustrated well in the prototype and early user feedback can be gathered with regards to the product. There are numerous advantages of rapid prototyping.

Benefits of Rapid Prototyping: Significant advantages of rapid prototyping include reduction of project cost and risk. Generally, one or more prototypes are developed in the process of software development in a series of incremental and iterative steps. Every prototype that is manufactured is based on the previous designs’ performance and it is a corrective process through which the past design defects or problems are corrected. The product is readied for production when the prototype is refined as per requirements and meets all the design goals like manufacturability, robustness and functionality.

Another great advantage of rapid prototyping is that it finds use and application in almost all the industries. The other advantages of rapid prototyping include the following.

Visualization capabilities are enhanced in the early designing phase with use of rapid prototyping. The user gets a fair idea of how the final product will look by observing the working model in early design stage. The design flaws can be detected before manufacture process is initiated. Rapid prototyping enables producer and users to participate actively.

Cutting Torches Information

Cutting Torches Information and all about Gentec Torches, and Acetylene Oxygen Torches at new section on Metal Casting website that is all about Casting Torchess. The new Cutting Torches Casting section can be accessed by users and non-users by visiting the following web address: with Cutting Torches.

Here is an excerpt from the Home Metal Casting Furnaces section page on Metal Casting Zone:

“Types of Torches: The torch can be defined as the part held and manipulated by the welder to get the weld made. It possesses a valve and connection for oxygen and the same things for fuel gas, a handle to obtain the grip, an integrating chamber (angularly set) where there occurs a mixing of oxygen and fuel gas, with a tip where formation of flame takes place. The fuel gases used along with oxygen include propylene, propane, hydrogen gas, MAPP gas, Liquefied Petroleum Gas (LPG), and the most widely used is acetylene.

Injector Torch: It can be defined as an archetypal oxy-fuel torch, also known as an equal-pressure torch. It carries out the mixing of mere two gases. The injector torch operates in such a way that high pressure oxygen comes out of the tiny nozzle present in the torch head, and the fuel gas gets dragged towards it via the venturi effect.
 

DIY Casting Furnaces

Usually, the incorporation of work coil takes place into a resonant tank circuit. There are innumerable advantages of this. The first advantage is that any one of the parameters, i.e. voltage or current is made sinusoidal. This causes fewer losses to inverter by the way of allowing it getting benefited from either zero-current-switching or zero-voltage-switching corresponding to the arrangement chosen. The visibility of sinusoidal waveform at work coil gives the proof of purity of signal. There also occurs less interference of radio frequency with the equipment in its vicinity. It’s up to the designer to choose one amongst several resonant schemes.”


The new Home Casting Furnaces webpage is there to provide users with all of the information they need on casting and learning the basics of DIY Casting Furnaces. It can be visited for free at:Home Metal Casting. This new section of Backyard Foundry information will continue to be updated with the latest and greatest information on the basics of DIY casting furnaces at: Home Foundry.

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Casting Furnaces and Metal Casting Furnace Types Just Released

Casting Furnaces Information and all about Metal Casting Furnace Types, and Casting at a new section on Metal Casting website that is all about Casting Furnaces. The new Casting Furnace section can be accessed by users and non-users by visiting the following web address:Casting Furnace.

Here is an excerpt from the Casting Furnaces section page on Metal Casting Zone:

“Electric Arc Furnace: This furnace can be described as a furnace heating charged materials by the way of an electric arc. These furnaces exist in all the sizes-right, from the smallest one having a capacity of around 1 ton to the largest one having a capacity of 400 tons. The former one is used in foundries to produce cast iron products, whereas the latter one is used for secondary steel making. The ones used by dentists and in research laboratories might be having capacity of a few grams only. The electric arc furnace can have temperatures risen up to 1800 Celsius. The first electric furnaces came into being in 1907, at the hands of Paul Heroult of French origin. The commercial part of these furnaces was established in the United States of America. In the beginning, the specialty product used in the making of spring steel and machine tools was electric steel. Calcium Carbide was also prepared in these arc furnaces. It (calcium carbide) was used in carbide lamps.

This furnace comprises of a refractory-lined vessel, normally water-cooled in huge sizes, having a covering of a retractable roof, through which the entry of graphite electrodes takes place. They might be one or many in number. The furnace is divided into 3 sections: the shell, consisting of lower steel bowl and sidewalls, the hearth, consisting of refractory lining the lower bowl, and the roof, that can be water-cooled or refractory-lined, and can easily be shaped into a spherical section or conical section (frustum). A refractory delta is also supported by the roof at its center, by the way of which graphite electrodes make an entry.”
 

Home Metal Casting Info Released

Home Metal Casting Furnaces Information and all about Home Foundry Furnace Types, and Home Foundry Casting Information at a new section on Metal Casting website that is all about DIY Casting Furnaces. The new Home Metal Casting section can be accessed by users and non-users by visiting the following web address:Home Metal Casting.

Here is an excerpt from the Home Metal Casting Furnaces section page on Metal Casting Zone:

“DIY Induction Furnace: Theoretically, only three things are required for implementing induction heating: High frequency Electrical Power Source, work coil for generating an alternating magnetic field, and a workpiece-electrically conducive. However, the practical approach is very complicated. For instance, the work coil and High Frequency source’ should have a matching network in between, to obtain better power transfer. Use of water cooling systems is very common in induction heaters of high power. This facilitates removal of waste heat from the matching circuit of the work coil and the coil itself. This process involves application of control electronics as well. Control Electronics, as the name suggests, controls the heating action’s intensity, thereby ensuring consistent results. It also provides protection against unpleasant operating conditions.

Usually, the incorporation of work coil takes place into a resonant tank circuit. There are innumerable advantages of this. The first advantage is that any one of the parameters, i.e. voltage or current is made sinusoidal. This causes fewer losses to inverter by the way of allowing it getting benefited from either zero-current-switching or zero-voltage-switching corresponding to the arrangement chosen. The visibility of sinusoidal waveform at work coil gives the proof of purity of signal. There also occurs less interference of radio frequency with the equipment in its vicinity. It’s up to the designer to choose one amongst several resonant schemes.”
 

Metal Casting Information Released

May 19, 2008 -- Metal Casting Zone has just released a new section of their website that has all of the basics on Casting, Metal Casting, and Die Casting. This is part of a new community website that is all about Casting. Members and non-members can visit this Casting page on the Metal Casting website for free at: Metal Casting

Here is an excerpt from the new Metal Casting information webpage:

“Casting can be defined as a process of manufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’ containing a desired shaped hollow cavity, and then made to solidify. The ejection or breaking out of the casting then takes place to get the process completed. The use of casting is ‘forming hot liquid metals’ or numerous metals that are cooled after having the components like clay, plaster, concrete, and epoxies mixed. Complex shapes are normally made by casting, as other methods are not feasible. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting.

‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.
 

Casting Molds

Permanent Casting Molds: Although these permanent casting molds are not as flexible as the sand castings which allow to be used in different metal patterns or designs but these lower the cost of producing the part. When there is a production run of more than 1000 parts the permanent casting molds would produce much lower piece of cost part. Apart from this, the break even point also depends on the density of the part. There are more complex parts that are favored when you use these permanent casting molds. The typical part size would be around 50g to 70 kg and the basic materials used are medium and small parts that are made from magnesium, aluminum and brass and also their alloys.

Slush Casting Molds: The slush casting molds are actually a special type of permanent casting molds in which the molted metal is not allowed to solidify completely. After gaining the desired wall thickness the still not solidified molted metal is then poured out. This is basically used in order to make void ornamental objects like lamps, candlesticks and statues.

Corthias Casting Molds: This type casting molds is yet another variant of the permanent casting molds in which basically a plunger is used to pack the molted metal through the spure hole. This type of process allows thinner walls and to produce greater details.

Vacuum Permanent Casting Molds: This is also another type of permanent casting molds which is also similar to low pressure permanent casting molds. In this type vacuum is used rather than a pressure. You can make thin wall casting through this type of casting molds like in the other low pressure casting molds. Apart from this the results are high as there are no risers used.