Some different methods can refer to casting, but which one is best for your project? There are merits and demerits to types of casting processes, so it can take time to choose which one is proper for you. We’ve created this blog to help you decide which type of casting method is best for your project. We’ll walk you through the basic information of each type of casting and explain the benefits and drawbacks of each one.
What Is The Casting Process?
The casting process is manufacturing in which a liquid material is poured into a mold and allowed to solidify.
The mold is usually made of metal and can be permanent or temporary. The casting process can be either hot or cold depending on the cast material. Hot casting involves pouring the liquid material into the mold while it is heated, while cold casting involves pouring it into the mold at room temperature.
Casting can create various products, including engine parts, cookware, and jewelry.
12 Different Types Of Casting Processes
In foundry work, there are 12 common types of casting processes. They are: molding in the sand, molding in loam, plaster, dry sand casting, investment casting, lost wax casting, shell molding, vacuum casting, centrifugal casting, and continuous casting. Some examples of special casting molds include investment casting, lost foam casting, metal mold casting, and ceramic mold casting, among others.
Sand Casting
Sand molding is a process in which sand is used to create a mold for casting metals.
| advantages | disadvantages |
| it allows for greater precision than other methods of molding | the process can be messy and difficult to clean up |
| relatively inexpensive | if not done correctly, sand molding can result in uneven or faulty castings. |
| easy to set up |
Molding In Loam
Loam casting makes objects by pressing moistened loam, or a mixture of sand and clay, into a mold. This technique can create sculptures, architectural elements, and other objects.
| advantages | disadvantages |
| relatively easy to use | dried loam is very powdery and can be difficult to work with |
| loam is very strong and durable, making it an ideal material for creating long-lasting castings | loam must be moistened before it can be used, which can add extra time to the molding process |
| does not require expensive equipment |
Molding In Plaster
Plaster casting is a process in which a mold is filled with plaster to create a negative copy of the original object.
| advantages | disadvantages |
| relatively inexpensive | plaster casts are not particularly strong and can break easily |
| easy to do | the plaster must be regularly wetted down in order to prevent it from drying out and cracking |
| the casts can be easily removed once the plaster has hardened | |
| plaster casting is a very versatile technique that can be used to create an endless variety of shapes and sizes |
Permanent Mold Casting
Permanent mold casting or gravity die casting, is a manufacturing process used to produce high-quality, dimensionally accurate metal components. This method uses a reusable mold, typically steel or iron, to shape the molten metal. The mold consists of two halves, and the cavity inside is designed to match the desired shape of the final product.
Once the mold is preheated, molten metal is poured into it, and gravity assists in filling the cavity. After the metal solidifies, the mold is opened, and the part is removed. Permanent mold casting offers advantages such as excellent surface finish, close tolerances, and the ability to produce complex shapes repeatedly, making it a popular choice for various industries.
Lost Foam Casting
Lost foam casting, also known as evaporative pattern casting, is a die-casting process that involves creating a foam pattern of the desired part, coating it with refractory material, and burying it in a molding material.
When molten metal is poured into the mold, the foam pattern vaporizes due to the high temperature, leaving a cavity in the shape of the desired part. The molten metal fills this void, solidifies, and takes on the shape of the original pattern.
Dry Sand Casting
Dry sand casting is a process where a mold is created using dry sand. And dry sand casting is a relatively simple process and can create small, intricate metal pieces.
The steps for dry sand casting are as follows:
These simple steps allow you to create high-quality metal castings using dry sand casting.
| advantages | disadvantages |
| it can be used with any type of metal | it is more difficult to achieve a high degree of accuracy, and the finished product can be susceptible to porosity |
Investment Casting
Investment casting, also named lost wax casting, is a process whereby a wax replica of the desired object is created. This versatile process creates everything from engine parts to dental implants.
The basic process involves:
| advantages | disadvantages |
| it allows for very precise replication of complex shapes | the process is relatively slow |
| the use of wax as a molding material results in a smoother surface finish on the final product | it can be quite expensive |
| Investment casting is well suited for small-scale production, as it does not require large amounts of materials or equipment |
Lost Wax Casting
Lost wax casting creates metal sculptures, jewelry, and other objects.
The basic steps of the process are as follows:
| advantages | disadvantages |
| relatively simple and quick | the process is somewhat messy and dangerous |
| it can be used to create highly detailed objects | it requires specialized equipment |
| allows for a high degree of repetitive accuracy, making it ideal for mass production | more expensive than other methods of manufacturing |
Shell Molding
Shell molding, also known as shell mold casting, is a metal casting process. The process forms the molds, which can then cast parts accurately.
| advantages | disadvantages |
| it allows for very accurate reproductions to be made | the process can be somewhat messy and difficult to control |
| shell molding is relatively fast and efficient | shell molding generally only works with small- to medium-sized parts |
Vacuum Casting
Vacuum casting is a process used to create objects from a liquid resin. It is a versatile technique that can create high-quality prototypes quickly and affordably.
The steps of vacuum casting are as follows:
| advantages | disadvantages |
| speed, accuracy, flexibility | The process is limited to thermosetting plastics and it can be difficult to produce complex shapes or large parts |
| relatively easy to use | it is important to carefully control the manufacturing process to avoid defects in the finished product |
| does not require special equipment or training |
Centrifugal Casting
Centrifugal casting is a process in which molten metal is poured into a spinning mold. It can create cylindrical, round, flat discs or other shapes objects.
The steps of centrifugal casting are as follows:
| advantages | disadvantages |
| cast objects with very thin walls | the process can be somewhat dangerous, as molten metal can cause serious injuries if it comes into contact with skin |
| relatively quick and simple | centrifugal casting is not suitable for all types of metals |
Continuous Casting
Continuous casting solidifies molten metal into a “semifinished” billet, bloom, or slab for subsequent rolling in the finishing mills.
The steps for continuous casting are as follows:
| advantages | disadvantages |
| higher productivity | the need for more expensive equipment |
| lower energy consumption | the potential for defects in the final product |
| less scrap |
Our Company’s Machining Capability For The Casting Process
At our Corporation, we are proud of our machining capability for the die casting process. We have some of the most technologically advanced machines in the industry, and our experienced team of engineers and technicians are experts in using them. This means we can produce cast products with extremely tight tolerances and intricate details.
In addition, our machining capability allows us to create custom-designed castings that meet the specific needs of our clients. If you need a casting supplier that can provide superior quality and service, don’t hesitate to contact us today. We are willing to discuss your specific needs and requirements.
Conclusion
So, what’s the best casting method for you? It depends on your needs and preferences.
With so many types of casting processes available, it can be challenging to understand which is the right fit for your project. However, by exploring the 12 different types of casting processes and understanding their unique characteristics and applications, you can make an informed decision that aligns with your needs.
Whether you’re in the automotive industry or the aerospace sector, there is a casting process that can meet your requirements. By leveraging this knowledge, you can ensure the success of your casting project and achieve high-quality results. So, whether you choose sand casting, investment casting, or any other method, consider each process’s advantages and disadvantages and select the one that best suits your needs.
