Why does Investment Casting Makes the Difference?

Many people understand the significance of manufacturing, but many fewer understand the significance of the casting business. It’s in charge of components that power daily life, the economy, and a variety of other businesses.

For sure, you know how important for the employment of people the factories and industries are, but do you know why? In this article you will learn how the process of investment casting takes part in your everyday life and why it is the most common one of all the castings.

但是首先,让我们了解什么是演员,什么是投资铸件。继续阅读!

What is investment casting?

通常,在铸造过程中将液体材料倒入霉菌腔中。通过化学反应或冷却,这种液体会随着时间的推移而愈合。固化部分(也称为铸件)是接下来被驱逐或从模具中拆除的,以完成该过程。

And when it comes to accuracy, investment casting outperforms all expectations. A mold with the desired design is created using wax, plastic, or even wood. The casing is then created and hardened in high heat chambers. The liquid metal is then poured into it and allowed to cool. This section is responsible for the technique’s accuracy.

What is the importance of metal casting?

Castings are part of our everyday life. From trucks and cars, to every building and agricultural land, a metal cast is part of it. This is an industry that supports all industries.

There are a lot of industries that wouldn’t survive the demand of these days without the metalcasting industry. To name a few: Automotive, Construction, Agriculture, Aerospace, Transportation and Healthcare.

All equipment needs parts and pieces, and they are all probably made from casting. And especially mass produced ones, which need a fast and efficient way to make perfect pieces everytime!

金属铸造的简短历史

Roughly 4000 BC

The first metal castings may be dated all the way back to roughly 4000 BC. Due to the difficulties in acquiring pure ore at the period, gold was the very first material to be cast for its flexibility. A copper frog, on the other hand, is the earliest known casting. It is thought to have been created in Mesopotamia about 3200 BC. Then, because of its stiffness in comparison to gold, bronze became the metal of choice for casting, and it was melted and formed into numerous tools and weapons using permanent stone molds.

到公元前2800年

铸造技术已经进入了埃及的道路,在整个青铜时代,他们在统治地位上的统治地位非常重要。中国的商朝是第一个在公元前1300年左右熔化金属时第一个使用沙子铸造的人。直到秦朝300年后,铸铁才被用作军事乐器或装饰品。

Over a thousand years later, the religions made a great impact in castings. As they used it to male art and prestige their gods, they started to use it to make their own cathedrals. Churches and cathedrals were built by the hand of casting workers.

Then the Wars started

People learned how to make guns and cannons out of casting. During World War 1 and 2 casting was used to make military archery. Weapons and machines were being mass produced by the industry that would soon be the birth of all technology today.

革命开始了

All industries started to benefit from the casting industry. Healthcare, with machines and equipment always improving. The military, with new weapons and devices for security. And even the transports, bus and cars began to look modern and have a lot more comfort in them thanks to castings parts. And now, we are here.

Today, you can find metalcasting things all over. From the cellphone in your hand, to the equipment that transport your food up to the grocery store. So now we can look a little back and understand all the types of casting there are!

Types of casting

不同的需要不同的技术需求。所以there are numerous types of casting. We have already talked a little about the investment casting, and now we will learn about the other methods used in the industry.

Sand casting

一种用于在沙模中生产铸件的技术。钢,铁和大多数非有产性合金铸件可以通过砂铸件产生。

This approach is ideal for fine details and intricately formed patterns. It has a low subjective cost and is most commonly utilized with automotive components and pieces.

在低压下铸造

该过程采用压力来确保铸造结晶,结果是最高质量的。它是薄铸件的理想选择,因为它使用了所需的所有融化金属,从而减少了废物。低成本设备也有助于总体成本效益。所需的工作也更少,其简单性有助于培训和材料利用。

Continual Casting

It operates by constantly pouring molten metal into a metal mold known as a crystallizer. The hardened (crusted) casting is continually dragged out of the other end of the mold and might be any length or a defined length.

The material is resistant and durable, which allows for speedy cooling. It is also a highly cost-effective method.

Investment Casting

Investment casting is a process that involves creating patterns in soldering materials, covering the surface of the pattern with various layers of ceramic products, and then melting the pattern out of the mold shell to create a mold without a dividing surface that can be filled after baking at high temperatures.

When it comes to surface size and geometric qualities, this one is more accurate. This approach also yields a lot of complex-shaped patterns.

Why is investment casting important?

精密铸造是一种制造方法,其能够以精美的细节重新创建复杂形图案。最好避免使用大型装备代价高昂的耗时任务。

它也可以用作艺术和装饰的媒介。尽管小公司所有者和工匠可以使用其他材料制作艺术品和珠宝,但投资铸件主要用于行业,尽管小型公司所有者和工匠可能会以较小的规模生产。

This is typically utilized nowadays to make metal components and machine parts.

投资铸件用于一系列行业,包括枪支,食品服务,天然气和石油以及能源部门。它可以在您的日常生活中找到,例如冰箱,汽车等等。他们无需在设施中单独创建昂贵的装备和大量员工的设施,而是可以生产数千个具有永久铸造甚至可支配的员工。

This method is really important for its quality control. It is possible to make perfect wax molds that can precisely leave a mark on detail in the mold. It can not be the most economical to the environment, since all the mold and casting is lost during this process. But the cost-efficiency value is worth it.

Simple steps, with high-demand and job opportunities. This is the perfect recipe to a great method of mass producing parts and pieces for all big industries!

What is the investment casting process?

We are going to explore a step by step guide on how the investment process is done. There are a lot of steps, but this is an interesting method! Keep reading to understand more!

首先,我们创建模式

许多金属铸造方法需要创建图案,这是用于创建模具的成品对象的副本。这些图案可以是永久性的或可验证的,并且可以由蜡,木材或塑料形成。

Then, the mold is made

根据技术的不同,模具是通过多种方法制造的。例如,可以使用CNC机器来创建永久金属模具,而通过将沙子混合物放在设计的外部,则可以创建沙子。霉菌制造是一种涉及模具的专业技术。

But for the investment casting, the molds are made by a wax representation of the final product. The wax is what gives it the smooth surface and refined, detailed, parts of every piece. After, it is taken to a high-heat chamber and then melted, leaving only the mold behind, to be filled with the material.

Next, we fill the molds

The metal or other material is heated until it melts before being poured or pressed into the mold. For example, in investment casting, the metal is melted and poured in the mold, filling every corner of it. Then it is allowed to dry up and solidify. After this step is fully completed, we can go to the next part.

现在,我们删除产品

The cast portion is taken from the mold once it has cooled and set. This implies that for procedures such as sand casting, the mold must be destroyed in order to access the component within; for permanent molds, the two halves of the metal mold are taken apart and ready for reuse.

For sand castings, the mold can be remade with the same sand. Once it is dissolved, the sand can be repurposed. But for the investment castings, the mold is destroyed in the process.

And finally, the final touches

If the product is made out of metal, the parts can be polished and refinished. This will give them the shine and final glow they need. If any flaws are found, the piece will be discarded.

金属铸件的应用

They are part of our daily life, in cars, refrigerators, transport, healthcare and much more. Castings are all over the world, and these are some of the categories we found to exemplified that:

  • Engine blocks
  • Turbine housings
  • Manhole covers
  • 消防栓
  • Valves and seals
  • Sewer and water pipes
  • Key parts in the energy grid
  • Medical equipment
  • Car pieces
  • Everyday electronics

And so much more! It is amazing when something we didn’t even know was a thing, is part of something big and important for each one of our lives.

你可能也知道有人在这工作industry and know that it has given a lot of jobs throughout the years.

Why is casting preferred over the manufacturing process?

Investment casting produces precise parts while decreasing material waste, energy consumption, and later machining. It may also ensure the production of very complicated components. As a result, design engineers may reap substantial benefits from the investment casting process.

制造过程涉及许多类似链的方法。它涉及锻造,焊接以及最常见的冲压。制造是使用人工,设备,工具以及生物学或化学处理或配方制造物品的过程。

它可以指将原材料大规模转换为已完成的商品,也可以通过向制造商出售基本商品来开发更复杂的物品,以制造车辆,飞机或家用电器等物品。

所以,是的。铸造是一种制造业!

制造商采用铸造的最令人信服的原因是它提供的令人难以置信的设计自由。这是一种非常适应性的方法,可以使用其他制造方式使用复杂的设计过程。此外,由于它包含一个相对简单简单的生产过程,因此可以快速从原材料转换为最终产品。

The act of pouring something into a mold and then releasing it after is what makes it so good. Making perfect molds, with the precision of the investment casting, can cut the production time in a huge economic way.

When you do this process with machinery, you can expect problemas with it, and be worried about hiring specialized employees to deal with it.

而且,一台机器的成本比短时间内生产的费用高。

由于组件或形状的组装没有限制,因此铸造还可以创建视觉令人愉悦的模式。为了从铸造中获得适当的饰面,可以使用各种铸造程序。砂造型的外观粗糙,而壳的成型和投资铸造的外观也更光滑。铸造还会导致成品的残留应力减轻。

The cost reductions are the most obvious advantage of employing the casting process.

大大降低了制造成本,因为它allows for the consolidation of several elements into a single fabrication. It also needs a shorter manufacturing lead time, which leads to lower prices. In addition, the design freedom and flexibility result in decreased machining and excess metal costs.

The investment casting process is great to make precise pieces with less work and cost. Is simple and it can be scaled to give profits in the short term.

结论

Metal casting is the process of melting metal, pouring it into molds, and allowing it to solidify in the mold to make the desired shape. It is widely utilized to produce large parts used in machinery and heavy equipment. Molds for this method are classified as disposable or permanent. The word derives from the reuse of permanent molds.

As for the investment casting, also known as precision casting, is a manufacturing method that shapes a disposable ceramic mold using a wax pattern. A wax pattern in the precise shape of the item to be cast is created and dipped in a ceramic substance.

After the ceramic material has solidified, it is turned upside down and heated until the wax melts and drains. The solidified ceramic shell serves as an investment mold that can be replaced. The mold is filled with molten metal, which is then allowed to cool. The used mold is then used to break the metal casting.

This process also has a very complex history.

Thousand of years ago, real civilizations used to make jewelry and art with this process. Even decoration and functional elements of their home used to have casting in them.

But today, with the increasing population and demand for technology, and even weapons, its use has changed. Transports, military, healthcare and a lot of other industries already mentioned before, use the parts made by the casting process. So these castings make a big part of our history and daily life.

There is a lot more to learn and understand about the metal world. But understanding the difference it can make in people’s lives is already incredible!

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