Quality metals are the bones holding up our infrastructure. Everything from bridges and skyscrapers to our automobiles and kitchenware relies on metal casting. An iron casting company creates molds and follows casting procedures on a variety of metals including steel. Casting companies can create custom designs and molds to sell to buyers. They have the technology to create a variety of different types of casting including sand, die, and investment casting.
Many industries rely on manufacturing and casting companies to create their products. It’s not uncommon for casting companies to partner with a specific company on a contract basis. Working with an iron casting company will ensure you receive the best metal components for your next project.
Are you thinking about investing in an iron casting company for your next big project? Here are the five top applications of an iron casting company to make your next project a success!
1. Create Custom Components at an Iron Casting Company
A challenge many engineers and manufacturing companies face is finding a way to create the custom parts needed for their industrial projects. Casting companies have the tools and skills necessary to create custom components. This is ideal for anyone needing specially made parts that have complex shapes or complicated internal shape.
Investment casting is a foundry process based on lost-wax casting. This process uses a one-use wax pattern to create each part. It’s one of the oldest forms of casting spanning over 5,000 years.
Not only will you have the freedom of crafting unique components, but you also have the flexibility to choose your materials. Investment casting is great for aluminum alloys, non-ferrous alloys, and cast iron. Any high-temperature alloys also work well for this process.
A casting company will work with you to ensure the product you receive meets your needs and specifications. This style of casting is incredibly flexible allowing you to choose almost any size, shape, and thickness of metal you’d like.
2. Inspecting and Testing of Components
Testing and inspection is a must if you want high-quality functioning components. The foundry will also follow steps to identify any potential defects before producing the component.
Throughout the foundry processes, the casting company will regularly perform density indexing, rotary degassing, and spectrographic analysis. Density indexing checks and reduces the porousness of the casts.
Rotary degassing uses gases like nitrogen to remove hydrogen in molten aluminum molds. This process will strengthen the aluminum and make the casting more durable and stronger.
Casting companies will test and inspect every component they cast. This ensures their customers receive the highest quality casts and components.
3. Variety of Casting Styles – Iron Casting Company
Casting companies offer an array of different casting styles. The specifications, size, and required materials for your project will determine which type of casting will work best for your components. Here are some of the most common casting styles.
This is best suited for silica-based materials and reduces the risk of flaws. Great for large components, casts both ferrous and non-ferrous metals, and costs less.
This style offers a high-level accuracy and is great for complex and thin-walled components. Offers a high-quality finish on final components.
Similar to the sand casting process but uses water, gypsum, and a strengthening compound to create molds. The benefits include creating complex shapes, smooth finishes, forming large parts, and a high level of accuracy.
A great option for casting cylindrical parts like pipes. This style uses g-forces to create a spinning mold where the molten metal pushes into the sides of the mold.
Non-ferrous metals such as zinc work best for this style of casting. Die casting uses high pressure to mold materials. Benefits of die casting include uniform design, less post-casting machining, and close shape and size tolerances.
Permanent Mold Casting
Using reusable molds, permanent mold casting is a low-pressure process. It’s great for creating hollow shapes. It works well with materials like aluminum and magnesium alloys, zinc, lead, cast iron, and some bronzes.
There are three main aspects of your project you need to consider before choosing a casting method. They include available time, the complexity of the part, and your budget.
4. The Right Surface Finish
The final step in the casting process is surface finishing. This process alters the surface of metal components to protect the metal and improve its aesthetics. Casting companies will add, remove, or reshape the metal’s surface to give it a great finish.
A quality surface finish helps metal products look better and last longer. The benefits of a finish include:
- Increase paint and coating adhesion
- Improve chemical resistance
- Resist corrosion
- Reduce and eliminate surface defects
- Better aesthetics
- Improve conductivity
- Boost strength and resists friction-based wear
Some casting styles will result in a better surface finish than others. The better the surface finish upon casting means there’s less need for machining after. This reduces time and keeps costs low.
Casting methods that offer great finishes needing less machining include investment, sand, graphite, and continuous castings.
5. Less Waste and Better Costs from an Iron Casting Company
Continuous casting is one of the most cost-efficient casting styles available. Additional benefits include saving time and boosting machining performance. There’s also less waste compared to other casting methods which save you money on material costs.
Continuous casting streamlines the process of creating bars and large metal slabs. You can use continuous casting on brass, aluminum, steel, and copper materials to boos efficiency.
Continuous casting doesn’t rely on creating each product in an individual mold. Instead, it creates larger shapes that you can cut to the proper size later. This reduces material costs and makes the process much faster.
Before continuous casting, ingot casting was the go-to casting method. The drawback to ingot casting is there was a high number of defects in the products. Continuous casting results in almost zero waste saving you both time and cost.
Choose Faircast, Inc. as Your Next Iron Casting Company
Working with an iron casting company will ensure you receive the best metal components for your next industrial project. You’ll be able to design and create any shape you need and know it will be durable and long-lasting.
Want to start your next project? Let’s get in touch and start planning today!