Casting

Description

Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.

The most common metals processed for casting are aluminum and cast iron. However, other metals, such as stainless steel, alloy steel,bronze, brass, magnesium, and zinc, are also used to produce castings in foundries.

Casting is most commonly used for making complex shapes that would be difficult or uneconomical to make via other methods. The casting process typically includes 4 steps - cutting, forming, assembling, and surface treatment.

-Mold making 

In the casting process, a pattern is made in the shape of the desired part. Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. The pattern is made of wax, wood, plastic, or metal. The molds are constructed through several different processes depending on the type of foundry, metal to be casted, the number of parts to be produced, size of the casting, and complexity of the casting. 

- Melting 

Melting is performed in a furnace. The process includes melting the charge, refining the melt, adjusting the melt chemistry, and tapping into a transport vessel. Refining is done to remove harmful gases and elements from the molten metal to avoid casting defects.  

-Pouring  

In a foundry, molten metal is poured into molds. Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. 

- Shakeout 

The solidified metal component is then removed from its mold. Where the mold is sand-based, this can be done by shaking or tumbling.  

- Degating 

Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches, bandsaws, or ceramic cutoff blades.  

-Heat treating 

Heat treating is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material.  

- Surface cleaning 

After degating and heat treatment, sand or other molding media may remain adhered to the casting. To remove any mold remnants, the surface is cleaned using a blasting process. Numerous materials may be used to clean cast surfaces, including steel, iron, other metal alloys, aluminum oxides, glass beads, walnut shells, baking powder, and many others.  

- Finishing

The final step in the process of casting usually involves grinding, sanding, or machining the component to achieve the desired dimensional accuracies, physical shape, and surface finish.

Technical Specifications

-Material for casting

Iron, mild steel, alloy steel, stainless steel, aluminum, bronze, brass, and zinc.

-Following processes are available for producing casting parts upon the nature of the design.

ØSand casting — Green or resin bonded sand mold.
ØLost-foam casting — Polystyrene pattern with a mixture of ceramic and sand mold.
ØInvestment casting — Wax or similar sacrificial pattern with a ceramic mold.
ØCeramic mold casting — Plaster mold.
ØV-process casting — Vacuum with thermoformed plastic to form sand molds. No moisture, clay or resin required.
ØDie casting — Metal mold.
ØBillet (ingot) casting — Simple mold for producing ingots of metal, normally for use in other foundries.

Except providing our clients with casting parts, most of products Auwell supplies with further machining and surface treatment service.

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Generally, Auwell does not offer forging, but only using forged parts as pre-material for further processing.

Advantages

-Rich Experience

More than 20 years of experience in casting products development and production, especially to the European and North American markets, with solid understanding of the material, technical and quality standards worldwide.

-Fast Turnaround

Generally, we provide a quotation within 3 working days. Combining the latest manufacturing technologies and facilities, Auwell can provide fast prototypes in just 2 weeks for simple projects.

-Comprehensive Solution Provider

Auwell provides comprehensive services for casting projects starting from designing, through prototyping, tooling/fixture development, sampling, mass production, and to logistic and post-sale support.

-Rigid QC Policies

The most rigorous quality policy starts from material control, and is followed through to final pre-shipment inspection. For quality control of casting parts, we provide set of test reports including chemical components, mechanical property, X-ray test, metallographic analysis report etc. For dimension inspection, we offer 3D scanning report, also CMM is available for inspection. We structure our processes, creating Flow Charts and Control Plans before production, making sure all QC processes are in accordance with ISO9001-2015 requirements and drawing specifications.

-Flexible Payment Term

Tooling payments need to be pre-paid. For mass production, we offer flexible payment terms, reasonable credit terms will be given, the client only pays when they are happy with the product they received. For long-term projects, we offer call-off inventory services for fast delivery requirements.

Applications

Casting fabrication products have widely been used in almost all industrial sectors including: 

- Aerospace and defense

- Automotive

- Agriculture Machinery

- Energy

- Electronics

- Construction

- Transportation

- Industrial

- Consumer Products

The following catalogues of casting products are the ones which Auwell has produced and supplied to our distinguished worldwide clients. Please click the relevant pictures for details. Please be advised, most of the products are for demonstration purpose only.

Stainless Steel Investment Casting

Stainless Steel Casting for GEBO

Steering Knuckle

Forging Spline Connector

Forging Wheel Hub

AGV Aluminum Base

Alu. Gravity & Sand Casting

Brass Gravity& Sand Casting