Casting is a method of pouring liquid metal into a cavity of a casting mold that corresponds to the shape of the part and leaving it to cool and solidify in order to obtain a part or blank. It is a key technology for manufacturing metal parts and is capable of producing complex shapes.

Ⅱ. History of casting

Casting technology originated around 4000 BC and was initially used to make tools and weapons. With technological advances, the casting process has evolved, and after entering the Industrial Revolution, casting has become an important part of machinery manufacturing. With the continuous improvement of technology, the casting process will become more and more precise, efficient and automated.

Ⅲ. What are the common casting methods?

Common casting methods mainly include sand casting, pressure casting, investment casting, centrifugal casting and disappearing mold casting.

Sand casting

Sand casting uses sand molds to produce castings for steel, iron and most non-ferrous alloys.
Its advantages are wide adaptability, low cost, especially suitable for the manufacture of complex shapes or blanks with internal cavities. Suitable for mass production.

Pressure casting

This method through the high pressure of the liquid metal quickly pressed into the precision metal mold cavity, the liquid metal cooled and solidified under pressure to form castings.
Pressure casting is suitable for the production of complex shapes of small castings.

Investment casting

Also known as lost wax casting, the process includes steps such as pressing wax, repairing wax, grouping trees, dipping slurry, melting wax, pouring metal liquid and post-treatment.
It is suitable for manufacturing precision castings and can produce parts with complex shapes.

Centrifugal casting

In this method, liquid metal is injected into a casting mold that rotates at high speed, and centrifugal force causes the liquid metal to fill the mold and form the casting.
Centrifugal casting is mainly used to produce round or ring-shaped castings, such as bearing rings.

Vanishing mold casting

This method uses a paraffin or foam model, which is vaporized by pouring under negative pressure to form the casting.
Evaporative mold casting is mostly used for precision castings. The molds are made of wax and will disappear after casting, eliminating the need to remove the mold and reducing dimensional errors.

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Ⅳ. Casting process

The basic process of casting includes the following steps:

Mold design: make the mold according to the product design requirements.
Molten metal: heating the metal to a molten state.
Pouring: Pour the molten metal into the mold.
Cooling and Curing: Wait for the metal to cool and cure in the mold.
Post-processing: Clean and trim the casting after it is removed.

V. What are the common casting materials?

Casting materials are categorized into the following 3 main groups:

Metal materials

Including a variety of pure metals (such as iron, copper, aluminum) and alloys. These materials have good casting properties, easy to heat and melt to form a liquid state, and then made into castings by pouring and cooling. Alloys such as cast iron, cast steel and aluminum alloys are widely used for their excellent strength, wear resistance and corrosion resistance.

Non-metallic materials

These include polymer materials such as resins and plastics. These materials are suitable for specific applications, such as the manufacture of plastic molds. Despite their good machinability and low cost, they are usually low in strength and are mainly used for castings that do not require high strength.

Composite materials

Including glass fiber reinforced plastics, etc. These materials combine the advantages of metal and non-metal, with excellent physical and chemical properties, widely used in the manufacture of high-performance, demanding castings.

The selection of casting materials depends on factors such as the performance requirements of the casting, the environment in which it is used and the production process. At the same time, the cost, source and environmental protection of the material are also important considerations. With the progress of science and technology, more and more new materials are introduced into the casting industry, providing more possibilities for the development of casting process.

VI. Advantages and disadvantages of casting

Advantages:

Capable of producing parts of complex shapes.
High material utilization, reducing waste.

Disadvantages:

Longer production lead time, especially for mold making.
Casting defects such as porosity may occur.

Ⅶ. What are the key technical indicators in casting?

In the casting process, key technical indicators include:

Casting accuracy: affects the fit and use performance of the finished product.
Surface finish: affects the appearance of the casting and subsequent processing.
Mechanical properties: such as strength and toughness, ensuring the casting’s safety in use.

VIII. Casting parts are used in a wide range of industries

Casting parts are widely used in a number of industries, such as automotive, aviation, agricultural machinery, construction machinery, engineering machinery, railroads and ships.

Automobile industry

The automotive industry is the largest application of casting parts, body, steering, suspension, brakes, engine and transmission and many other parts are dependent on the manufacture of casting parts.

Aerospace industry

Casting technology in the aerospace field also occupies an important position, widely used in the manufacture of engine impellers, nozzles, hydraulic cylinders, racks and signal disks and other complex components.

Agricultural machinery

A large number of parts in agricultural machinery such as tractors, plows, cultivators, combine harvesters and planters are manufactured through the casting process.

Construction Machinery

Construction machinery industry commonly used casting parts to manufacture excavators, loaders, bulldozers, road rollers and concrete pumps and other key components of large equipment.

Railroad industry

In the railroad field, castings are used in a wide range of applications. Typical examples include key components such as railroad wheelsets, rails and turnouts.

Marine

An important consumer of cast parts, the marine industry uses castings to manufacture important structural components such as engine hatches, slip lines, rudders, marine motors and chain plate anchors.

Although casting parts have a wide range of applications in various industries, one of the most used industries is the automotive industry. This is because automobile production requires a large number of metal castings, including engine, transmission mechanism, suspension, brake system, steering, body and other components, and these components are complex and numerous, all of which need to use casting technology to manufacture.

IX. Future development trend of casting industry

With the steady development of the global economy and the transformation and upgrading of the manufacturing industry, the demand for casting products in the automotive, machinery, construction, aerospace and other industries is increasing. Especially under the impetus of new energy vehicles, industry 4.0 and other emerging fields, the market demand for high-end casting products has shown explosive growth. This brings huge market opportunities and development potential for the casting industry.
The future trend of the casting industry will be jointly driven by technological progress, market demand growth and policy support, and the industry will usher in more development opportunities and challenges.

X. Summarization

As the foundation of manufacturing industry, casting is facing new challenges and opportunities. Through continuous innovation and technological upgrading, casting will continue to play an important role in the future to promote the progress and development of the manufacturing industry.