Gray Iron,

Gray iron or grey iron was the original “cast iron”. It is an alloy of carbon, silicon, and iron, containing from 1.7 to 4.5% C and 1 to 3% Si. It is relatively easy and inexpensive to make. Compared to the more modern engineered irons, gray iron has a lower tensile strength and lower ductility. Read more

Product Analysis is the process of identifying, looking at or disassembling a product and identifying its main features. The aim is to understand more about a product and improve it in the future. Many factors influence the development of a product, some are listed below. Read more

Die-casting is similar to permanent mold casting except that the metal is injected into the mold under high pressure of 10-210Mpa (1,450-30,500) psi . This results in a more uniform part, generally good surface finish and good dimensional accuracy, as good as 0.2 % of casting dimension. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size.
Die-casting can be done using a cold chamber or hot chamber process. Read more

How to control the lost wax casting :
Casting size and shape determines the tolerance required to allow for process variables. Many process factors affect investment casting tolerances, such as:

1.Wax temperature Read more

Sand casting is used to make large parts (typically Iron, but also Bronze, Brass, Aluminum). Molten metal is poured into a mold cavity formed out of sand (natural or synthetic). The processes of sand casting are discussed in this section, include patterns, sprues and runners, design considerations, and casting allowance.

Patterns

casting pouring system

The cavity in the sand is formed by using a pattern (an approximate duplicate of the real part), which are typically made out of wood, sometimes metal. The cavity is contained in an aggregate housed in a box called the flask. Core is a sand shape inserted into the mold to produce the internal features of the part such as holes or internal passages. Cores are placed in the cavity to form holes of the desired shapes. Core print is the region added to the pattern, core, or mold that is used to locate and support the core within the mold. A riser is an extra void created in the mold to contain excessive molten material. The purpose of this is feed the molten metal to the mold cavity as the molten metal solidifies and shrinks, and thereby prevents voids in the main casting.

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