Investment Casting
Investment Casting is an industrial process based on lost wax casting, one of the oldest known metal transformation techniques, more than 5000 years old. In its earliest forms, beeswax was used to form the patterns needed for the casting process. Today, more advanced waxes, refractory materials, and special alloys are commonly used to make patterns. Investment casting is valued for its ability to produce components with precision, repeatability, versatility and integrity in a variety of metals and specialty alloys.
Process | Investment casting |
Metals | Ferrous metals (steel, cast iron) |
Max. size of casting | 600x600x600 mm |
Max. weight of casting | 50 kg |
Sand Casting
Sand casting is a metal casting process characterized by the use of sand as a mold material or the so-called form. The term “sand casting” can also refer to an object made by the sand casting process. More than 60% of all metal castings are produced using the sand casting process. Sand molds are relatively cheap and refractory enough to be used in steel casting. In addition to the sand, a suitable binder is mixed or used (depending on the molding process). Sand is usually poured into the frame. A cast negative is created by pouring sand around a permanent patterns, which can be made of wood, plastic or metal, again depending on the manufacturing process.
Process | Sand Casting |
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Metals | Ferrous metals (steel, cast iron) Non-ferrous metals (aluminium, copper…) |
Max. size of castings | Frame 4000×4000 mm |
Max. weight of castings | 40.000 kg |
Centrifugal Casting
Centrifugal casting or rotational casting is a casting technique commonly used to cast thin-walled cylinders/rolls. Unlike most other casting techniques, centrifugal casting is primarily used to produce rotationally symmetrical raw materials in standard sizes for further machining, rather than shaped parts tailored to a specific end use.
Process | Centrifugal Casting |
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Metals | Ferrous metals (steel, cast iron), Nickel alloys, Superalloys, Bi-metallic products |
Max. size of castings | Max. diameter 1000 mm, lenght 4000 mm |
Max. weight | 1500 kg |
Gravity Die Casting
Gravity casting is among the oldest known processes for the production of metals and metal alloys. It involves pouring molten metal from a crucible into a mold (in this case, a metal mold) under the influence of gravity alone, without the use of pressurized gases, vacuum or centrifugal force.
Process | Gravity Die Casting |
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Metals | Non-ferrous metals (aluminium,..) |
Max. size of casting 500x500x500 mm | |
Max. weight | 50 kg |
Pressure Die Casting
Die casting is a metal casting process characterized by pushing molten metal under high pressure into a metal mold. Most die castings are made from non-ferrous metals, particularly zinc, copper, aluminum, magnesium, lead, tin and tin-based alloys. Depending on the type of metal being cast, a hot or cold chamber machine is used. Due to the high price of the tool, it is only suitable for large-scale production.
Process | Pressure Die Casting |
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Metals | Non-ferrous metals (aluminium,..) |
Max. size of casting | – |
Max. weight | 20 kg |
Lost Foam Casting
Casting with combustible cores is a casting process similar to investment casting technology, except that polymer foam (styrofoam) is used for the pattern instead of wax. This process takes advantage of the low boiling point of polymer foams to simplify the casting process by eliminating the need to melt wax from the mold, while significantly larger pieces can be produced.
Process | Lost Foam Casting |
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Metals | Mostly steel and cast iron |
Max. size | Frame 4000×4000 mm |
Max. weight | 20.000 kg |
Sintering
Sintering is the process of forming a solid mass of material by pressure or heat without heating to the melting temperature. Since the sintering temperature does not necessarily reach the melting point of the material, sintering is often chosen as the process for forming materials with extremely high melting points, such as tungsten and molybdenum. The study of sintering in powder metallurgical processes is known as powder metallurgy.
Process | Sintering |
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Metals | Ferrous metals (steel, cast iron) Non-ferrous metals (aluminium, copper,..) |
Max. size | – |
Max. weight | 1 kg |