Traditional Casting Methods | Precision Investment Castings

There are a range of different types of traditional casting methods available. Casting is a manufacturing process that is typically used to create hollow and intricate shapes. The process involves liquified materials in which it is poured into the cavity of a specially designed mold and allowed to harden. Each type of casting and the individual casting processes provide their own benefits and it&#;s recommended to explore different methods available before deciding on the casting method that you want to choose for the manufacturing process. Here at Precision Investment Casting, we specialise in Investment Casting but there are a whole host of other options that include;-

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• Sand Casting.
• Plaster Casting.
• Die Casting.
• Centrifugal Casting.
• Permanent Mold Casting.
• And Many More

Investment Casting

The investment casting process has been around for decades and PI Castings have over 65 years of experience manufacturing components through the investment casting process. Through our vast experience, wealth of knowledge and state-of-the-art casting machinery, we are able to accurately and successfully produce castings from both non-ferrous and ferrous metals. The process for investment casting is fairly straightforward with a proven 8-step process that starts in the wax room and finishes with testing where castings are carefully fettled, blasted and heat treated. Setting operations here may also be required.

Main Advantages:

• Wide range of parts and materials (stainless steels, magnetic irons, brass and more).
• High-quality surface finish guaranteed with investment casting.
• High geometric and dimensional accuracy.
• Thorough testing carried out throughout the process.

Sand Casting

This type of casting method is ideal and recommended for producing castings in a sand mold, steel, iron and most non-ferrous alloy castings. The process of sand casting involves several stages in order to achieve a high quality finish. One of the first stages with sand casting may start with pattern-making which then proceeds to pouring, melting and cleaning. Sand casting is one of the most popular and most traditional types of casting methods that offers relatively inexpensive production costs when compared to other methods. 

Main Advantages:

• Well known for its low cost in higher volumes.
• Also provides wide adaptability.
• Has the ability to fabricate large components.

Disadvantages:

• Can produce potential poor surface finishes.
• Low dimension accuracy due to shrinking.

Plaster Casting

Plaster casting isn&#;t too dissimilar to the sand casting process in the sense that it uses a mixture strengthening compound and gypsum with the real difference being the use of water as a substitute for the sand. With plaster casting, an anti-adhesive compound is applied to prevent mold from being stuck against it and the plaster is also capable of filling in any gaps too. When the surface finish is one of the most important requirements, plaster casting is recommended but it can be much more costly than other types of traditional methods such as sand casting.

Main Advantages:

• Smooth surface finish is guaranteed.
• Has the ability to provide complex shapes.
• Capacity for forming larger parts.

Disadvantages:

• Only used for lower melting temperature materials.

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Die Casting

Die casting &#; also known as a metal casting process &#; is a proven and traditional casting method that normally involves non-ferrous metals which could include aluminium, copper, tin, copper and zinc. The high pressure metal liquid is pressed into a precision metal mold cavity at high speed and the metal liquid is cooled and solidified under pressure to form the desired casting. Die casting involves a highly technological process and whilst it is a proven method, it can also be a very costly one.

Main Advantages:

• Shape tolerances and close sizes.
• Reduces the requirement for post-casting machinery.

Disadvantages:

• Large parts can not be cast.
• Lead time can be lengthy.

Centrifugal Casting

If you&#;re looking to produce longer cylindrical parts such as cast iron pipe, the centrifugal casting process may be what you require. With this process, molten metal is poured into a rotating mold before the mold is then solidified and filled under the action of Centrifugal force. When it comes to manufacturing metal parts and components, Centrifugal is one of the go to traditional methods even to this day.

Main Advantages:

• Castings have high density and high mechanical properties.
• Ideal for the manufacturing of sleeves and barrels.

Disadvantages:

• Not all alloys can be cast in this way.
• Only certain shapes can be casted using this method.

Permanent Mold Casting

This type of casting method shares numerous similarities with Centrifugal and die casting. Permanent mold casting involves a low pressure-process that can be done by hand or machinery using multiple molds on a turntable. This process involved simple equipment if required and really easy automation. 

Main Advantages:

• Allows shells to be harder while the core remains liquid.
• Low-pressure process involved.

Disadvantages:

• Limitations may be present for high melting point metals.
• Complex and intrinsic shapes can not be cast.

Here at PI Castings, we provide high-quality and industry-leading investment casting. We are one of the longest serving manufacturers of investment casting in Europe with decades of experience. We highly recommend investment casting to create complex and detailed cast metal components for a variety of different applications and industries. Call us today on 925 .

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