Research and Development On Steel Castings

Posted: June 16, 2016 in Manufacturers, Steel Castings
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Nowadays steel is the demanding material which is used in the metal casting process. Let’s try to understand this research and development process using the sand material as base mould. In this process, any tub is filled with sand and make that sand wet. Then one sample object is pressed into this wet material to create the product design or shape. When the sand becomes dry, the molten metal is poured into this shape and waits till this liquid is frozen. Generally, the sand material is used to make rough casting products and then refined by another process like:

  • Machining
  • Machine grinding
  • Planting
  • Forging
  • Polishing

Pattern making

After getting the shape or design, the craft person or pattern maker produce one master object, generally from the wood. That cast will be shrink somewhat when the product starts to solidify and take the time to cool. This product is slightly larger than finished product.

The pattern can be made of Wood, wax, metal, plastic, foam etc. It generally depends on the size or quantity of the parts, molding process, and other factors.

sand-castings-mold

Moulding

The moulding box is made in several segments and these all must be latched to each other. If you want to make any simple object which is flat from one side, then the bottom portion is filled with sand or may be the mixture of sand and clay. After placing the pattern on the sand, the another moulding segment is added and additional sand is rammed around the pattern.

Then one additional cover is placed over it and it is unlatched, so the mould halves may be parted. If required then additional sizing may be added and pattern defects are corrected.  Sand may be bonded by chemical binders like amine hardened resins.

Cooling

Most of the iron or steel castings products become tough and ductile. But sometimes with few hard surfaces, it is possible to cool metal plates where the metal is to be hardened. Generally, 2 zones are available for cooling like primary cooling zone and secondary cooling zone.

Cores

To make cavities within a product such as engine blocks or cylinder heads this negative form is used. Generally, cores are inserted into the casting box after pattern removal. But if possible, then the design is made which avoid the use of cores.

With this completed mould at proper moisture content, this mould is positioned with molten metal, usually – tin, lead, brass, bronze, steel and iron. After filling with liquid metal, set aside until the product becomes strong. Then the sand is removed to reveal the product. If the product is made with steel then it may be glowing red.

Steel casting has many advantages like design elasticity, metallurgical flexibility, weight flexibility, economic, reliability benefits and many other.  Steel casting is widely used in many industries like energy, marine, construction, transportation, etc. Contact to Steel Castings manufacturers India to get the best steel casting products.

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