Darcast Crankshafts limited, Castings, Foundries, Engine Components, Automobile Components
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Castings

Castings, a process by which a fluid melt is introduced into a mould, allowed to solidify in the shape inside the mould, and then removed producing a fabricated part or casting. It is used extensively in the automobiles manufacturing industry, such as the castings of engine blocks, cylinder heads or vacuum-forming of plastics and in the lost core process. Four main fundamentals are required in the process of castings: pattern, mould, cores and the part. The casting pattern is the original template from which the mould is prepared. It creates a corresponding cavity in the casting material. Cores are used to produce tunnels or holes in the finished mould and the part is the final output of the casting process.

 

The castings process is subdivided into two distinct subgroups

1. Expendable mould casting
2. Non-expendable mould casting

 

Expendable Mould Castings

Expendable mould castings is a generic classification that includes sand casting, plaster castings and shell moulding.

 

Sand Castings

A method of casting typically used for casting wrought iron, in which the mould is constructed from compacted sand. By its nature, the mould can only be used once and needs to be reformed for each casting.

 

Plaster Castings

Plaster cast is a copy of a sculpture, which is cast in plaster. A plaster cast can accurately reproduce the details of the original sculpture but plaster casting is usually much less durable.

 

Shell Moulding

Shell moulding is a precision sand casting process capable of producing high quality castings with a superior surface finish. The essential feature of the process is the use of fine-grained, high purity sand that contributes the attributes of a smooth surface and dimensional accuracy to moulds, cores and castings alike.

 

Nonexpendable Mould Casting

Nonexpendable mould casting differs from expendable processes in that the mould need not be reformed after each production cycle. This technique includes different methods: permanent casting and die casting.

 

Permanent Mould Castings

A reusable mould is used in permanent mould casting. The advantages of this process include near-net shape components, better surface finish and improved mechanical properties.

 

Die Castings

Die-casting is related to permanent mould casting except that the metal is injected into the mould under high pressure. This results in a more uniform part, generally good surface finish and good dimensional accuracy of casting dimension. High pressure die casting is most suitable for non-ferrous metals. Since the die casting process is completed under high pressure, intricate details can be cast into the metal and little additional machining is necessary on the finished part. Zinc die castings, and aluminum die castings are most commonly used die castings. Metals recommended for die castings include alloys of aluminum zinc, magnesium and lead.

 

Darcast is very old in the field of castings. We can produce castings in various materials. Also, we can offer custom casting solutions.