Casting was one of the first industrial ways to make things. It was used in China, India, and Pakistan at least 7,000 years ago. Casting has been used to make tools, weapons, works of art, and other parts for a long time.

In the modern casting process, there are many different ways to do it, but in all of them, liquid material is poured (or injected) into a hollow cavity with the shape that is wanted, and then it is left to cool and harden into a solid part. The part that is solid when it is taken out of the mould is called a casting blank

What is Casting?

Casting is a way to make things. Liquid material is usually poured into a mould that has a hollow space in the shape that is desired, and then it is left to harden. The solidified part is also called casting. To finish the process, the casting is either thrown out of the mould or broken out of it.

Most casting materials are metals or cold-setting materials like epoxy, concrete, plaster, and clay that harden when two or more parts are mixed together. Most of the time, casting is used to make complicated shapes that would be hard or expensive to make any other way.

Casting in Simple Words

Casting is a method of making things in which a liquid, like molten metal, is poured into a specially made mould and left to harden. After the piece has hardened, it is taken out of the mould and finished in different ways or used as a finished product.

Most of the time, casting is used to make complicated solid and hollow shapes. Cast products can be found in a wide range of places, such as auto parts, aerospace parts, etc.

Advantages

    • Casting lets you make complicated shapes that would be hard or expensive to make any other way.
    • You can make things with hollow sections or cavities inside.
    • Large parts can be made in a single casting.
    • Most of the time, casting is cheaper than other ways to make things.
    • Foundries that make casts often use recycled materials to cut down on waste that would otherwise end up in landfills.

The Process of Precision Casting

Die Casting

Die casting is done by pouring or injecting molten metal under high pressure into a precise metal mould cavity at high speed. The liquid metal is then cooled and solidified under pressure to make a casting. This means that each part can be made with high accuracy and consistency.

Die casting has many advantages over other ways of making things, such as machining and stamping. For example, we can make complex shapes with complicated internal and external features and minimal draught angles, which means we don’t have to do as many finishing operations. Die casting can also save a lot of money on both the price of each part and the cost of making the whole thing.

Most of the things that are made in our die-casting factories are made of zinc and aluminium alloys. Zinc die casting makes parts that are strong, last a long time, and don’t cost too much. These parts have a good mix of strength, toughness, rigidity, castability, and good finishing. Aluminum die-cast parts have their own benefits, which let us make parts with complicated shapes that are light, resistant to corrosion, and good at transferring heat and electricity.

Sand Casting

Sand casting is less accurate than die casting because the moulds are mostly made of sand, with a small amount of clay added. When compared to other processes, using sand moulds has a lower initial set-up cost and a shorter lead time between product development and the first production run. Sand casting can make parts that are hundreds of feet long and weigh thousands of pounds.

First, a master mould is made. This master mould is then used to make production moulds out of sand. The mould cavity is made by putting sand around this master mould and then taking it away. The casting part is then made by pouring the molten metal into the sad cavity. When the part is done cooling, the sand mould is broken, and the part comes out. Sometimes, you need a core to make a more complicated feature (i.e., an inner hole).

Most of the things that are made in our sand casting factories are made of ductile iron, steel, aluminium, and bronze. Usually, the sand casting blanks need to be finished again to get rid of the parting line, smooth out any rough spots, and get close dimensions. People usually use sandblasting, shot blasting, and machining (lathing, milling, etc.). After finishing, a surface coating can be put on, such as black oxide, powder coating, or wet painting, to make the metal less likely to rust.

Cold Casting

Cold-casting moulds are very cheap and are made by pouring liquid silicone around a master mould to make a reverse mirror image. Silicone moulds last a long time, are easy to make and use, and can make very fine details on the part’s surface.

Poly resins with two different liquid parts are mixed together and poured into silicone production moulds, where they go through a chemical reaction to harden and make an exact copy of whatever was used to make the mold. Air bubbles in the liquid resin mixture are removed using vacuum chambers. In the same way, using thin-walled, low-cost steel moulds and the cold cast method, silicone products can be made quickly and well.

Cold-cast resins are great for making exact copies of complicated shapes and figures quickly and at a low cost to start up and make the parts. Resin castings are high-quality and cost-effective because they can be made the same way over and over and are heavy. They can also be decorated in many ways, from hand painting to decals. We use a wide range of polymers to make cast resin products with different flexibility and feel.

Casting Parts Manufacturer and Supplier in India – INDGIRKA

INDGIRKA Corporation stands as a premier casting parts manufacturer and supplier in India, delivering precision and quality. Our commitment to excellence ensures reliable solutions for diverse industries, making us a trusted partner in the realm of casting parts manufacturing.

We offer our clients from many different business industries a full range of services for casting parts.

We own facilities that are fully stocked and have high-tech manufacturing capabilities. This lets us make high-quality products for our customers in the usual amount of time. Our engineers at INDGIRKA are experts at making investment casting parts that are very accurate for both small and large products made of different materials.

We offer our wide range of Casting Parts and Sheet Metal Components in India as well as abroad. Contact Us Now.