As industries grow and develop, so too do expectations.
The pressure is on to continually evolve and supply improved parts that not only advance quality but deliver more complex and capable designs.
Fortunately, with multiple casting processes available, there’s more than one way to meet these manufacturing demands.
Question is, how do you know which one to use?
Here die casting experts Lupton and Place, offer an overview of the different casting processes available, to help you determine the right method for your needs.
What is casting?
Casting is a manufacturing method favoured for its ability to produce detailed parts in bulk.
The process involves pouring a liquid material (often a metal – but it can be plaster, concrete, clay etc) into a mould which then solidifies into the desired shape.
Casting may be an age-old process but it’s just as relevant today and is heavily relied on by businesses across the globe as a cost-effective means of mass-producing complex parts.
Popular casting processes
Some of the most common casting processes available include:
· Sand casting
Sand casting uses a mould made from silica-based materials, like naturally bonded or synthetic sand (hence the name!). It’s a versatile process which can be used with any metal alloy and typical applications include casts for car parts such as cylinder heads, crankshafts, and engine blocks.
It has the advantage of relatively low production costs even if you’re only producing minimal volumes but tends to offer less accuracy in comparison to other processes. The resulting surface is also often a little rough.
· Gravity die casting
Once again, the clue is in the title – gravity die casting relies on the force of gravity to produce an accurate cast as molten metal is poured directly into the mould.
Frequently the preferred choice for parts such as pipe fittings, engine pistons and gear housing, gravity die casting offers improved surface quality, thin walls, and tight tolerances.
Reusable moulds (referred to as dies) also mean productivity can be increased, whilst production costs are kept low – however the initial outlay for the dies is more expensive.
· Pressure die casting
Often confused with gravity die casting, pressure die casting is in fact a separate process.
Rather than the mould filling from the bottom up – as in gravity die casting – with this method, molten metal is injected under high pressure. The advantages of this are high efficiency and improved product quality, combined with faster production thanks to rapid cooling. However, the process is limited to non-ferrous materials.
· Plaster casting
Plaster casting is similar to sand casting, but this time the mould is made from plaster of Paris.
The plaster has low thermal conductivity, which allows molten metal to cool more slowly (although it’s not suitable for high-temperature ferrous materials). A key difference between this and sand casting is the surface quality of the finished part – with plaster casting the end result is much smoother. This method also has improved accuracy, making it suitable for small complex parts.
· Structural die casting
Often the sought after casting method for the construction industry, structural die casting is also employed for components used in car assembly and for airplane parts.
The favoured metal for structural diecasting is aluminium, due to the lightweight yet durable qualities it offers.
The process produces parts which rely on precise design and helps to ensure greater accuracy and sophistication. However, this more detailed approach understandably incurs higher production costs.
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Which casting process is right for you?
If you’re unsure which casting method is right for your application, why not speak to the experts at Lupton & Place?
At Lupton and Place, we specialise in a number of these processes including gravity and pressure die casting and can help to identify the best solution for your needs.
To talk in more detail with a member of the team call 01282 422361 or fill in our contact form and we’ll get back to you as soon as we can.