It might surprise you that metal casting has been around for over 5000 years!
In over a hundred-and-four generations, we’ve turned it from a small-scale, low-tech endeavor to an automated, high-tech masterpiece. Casting iron for barbells and fitness equipment is what a lot of people think of, but the truth is that casting is a lot bigger than that.
A testament to metal casting is how it’s in-demand across the world, after 52 centuries. In all that time we’ve learned a few tricks to it all, too.
We bet you’re already typing metal casting near me to find out how many foundries are casting. Before you do, check out some of these modern-day casting processes.
Keep reading to find out!
Shell Mold Casting
Shell mold casting makes parts for industries that require parts with a high level of tolerance; using elevator and escalator parts. In shell mold casting, there’s a metal form pattern.
Once we make the pattern, resin-coated sand pours into a dump box. We clamp the pattern on top as a “lid,” and then flip the box and heat it to over 550°F.
The resin-coated sand fuses together against the pattern. When we remove the pattern, one half of the shell is formed. We repeat the process is for the other half.
Once there are two halves of the shell formed, the shell is clamped together, put into a flask, a filler is added to stabilize the shell and reflect heat. The metal is poured into the shell, and voila!
You have a part that has a good surface finish, high-tolerance, and a process that is highly automatable.
DISA Mold Casting
The DISA molding process is a little different but also uses sand. In DISA molding, there is a molding chamber on the bottom which compresses “green sand” into a casting mold.
Once it’s fully compressed, the chamber plate at the back swings open, and the front chamber plate pushes this mold out. It will go on a conveyor system, butted against previous molds. Molds have cores set into them autonomously while another mold is being prepared behind it.
The molds fill with molten metal and then cooled. All steps happen at a timed rate so everything moves at the same speed.
Once the casting finishes and separates from the mold, we break the mold down and reuse it in the next cycle. This is a flask-less system, which avoids storage and maintenance on the molds.
Because the process is fully automated it reduces the costs associated with labor and increases production speed. With the DISA mold casting system, we can make over 550 molds in a single hour.
Metal Casting Near Me: Found
Now that you know a bit about the casting processes to look for, you’re allowed to type in metal casting near me. These three processes are just a taste of what the world of foundries has to offer.
Faircast, Inc. is your local Fairfield, Iowa foundry. We’re capable of meeting your high- or low-quantity ductile or grey iron casting needs.
From quote to shipping, we’re with you the whole step of the way. Request a quote today!