In this age of technology, the strength of materials that are used to make automobiles, electronic devices and other types of machinery is very important. It is also recommended to keep the strength high of the products that are manufactured. Companies producing engineering castings in India understand the significance of metal strength and thus they enhance the strength of the materials is by using casted metal rather than normal metal.
What is casting?
It is a manufacturing process where a solid is melted, heated to a proper temperature and then is poured into a cavity or mold. The cavity contains it in proper shape during solidification. In this one step, one is able to manufacture simple or complex shapes from any metal that can be melted. The product that is obtained can have virtually any configuration that the designer/manufacturer wants. This process also increases the resistance to working stress while also controls directional properties, and produces a pleasing appearance.
Metal Casting methods
There are generally 4 metal casting methods which are used by most companies. These are:-
- Conventional Molding Process
- Precision Molding Process
- Chemically Bonded Sand Molding Processes
- Innovative Molding and Casting Processes
Conventional Molding process
These are the most conventional molding processes which are the most widely used engineering casting process in India. One such conventional method is the Green Sand Molding. It is the most diversified molding method used in current metal casting operations. This type of molding utilizes a mold made by compressed or compacted moist sand that is packed around a wood or metal pattern. There is a presence of moisture in the molding sand which indicates that the mold is not baked or dried. This presence of moisture in the molded sand is also the reason why this process is called green sand molding.
Precision Molding process
In this type of moulding process, the manufacturers produce castings with an improved surface finish, while also providing excellent detail, with a higher degree of dimensional accuracy. There are 6 main types of precision molding process. These are:-
- Die Casting
- Squeeze casting or Squeeze forming
- Investment Casting
- The “V” process
- Shaw process- ceramic molding
- Hitchiner Process
Chemically bonded Sand Molding Process
This is the most recent process and has a lot of acceptance in the foundry system. The chemical system used is very simple which helps in making quality control less complex while also resulting in a more consistent product. The types of this kind of moulding process are:-
- Shell Molding
- Sodium Silicate CO2 Bonded Molding
Innovative Molding and Casting Processes
These are those processes which either use none of the other types of moulding process but something the manufacturing company itself found or uses one which is a mixture of other types of molding process. Some examples of this type of molding process are:-
- Expandable Pattern Casting
- Vacuum (“V”) Process Molding
- Centrifugal Casting
- “H” Process Molding
- Metal Injection Molding
Engineering Castings in India considered as initial part of casting industry since it helps in improving the quality of the metal which is being cast. This is important because of the use of these metals in the various industries all over the country.