Casting is a chemical process of pouring molten metal in an amalgamation of other chemical substances. Since the metal is molten and fluid, the desired shaped can be obtained. It is used in several industries new technologies are being researched upon by the pioneer casting manufacturers India to improve the processing of metal casting and maximize the efficiency.
To begin with, the application areas of casting metals like iron and steel are as below:
- Food processing
- Electronics
- Oil and gas
- Railroads
- Construction purposes
- Drilling
- Transportation
- Mining industries
The engineering components that is made from the process of casting are gears, valve bodies, pump casings, mining machinery, marine equipment, engine cylinder blocker, forging presses, and railroad truck frames.
Areas of improvement which require technology – The process of casting is age old and as we grow towards technology and aim at environmental factors, there is increasing need for some improvements in the methodology. These will need technological experts and the leading casting manufacturers India are cultivating techniques to simplify the process. The areas of improvement in the existing process of casting can be summarised as below:
- Identifying chemical substances which are less reactive and can be amalgamated easily. Generally when it comes to steel casting, molten steel is generally reactive to most substances and hence the alloy on which it is poured needs to be designed carefully!
- Power control via sensor to ensure the optimum level of heat is applied for melting and it's neither over heated nor under heated!
- Need to identify technological applications which will improve the processing as well as provide greater capacity to load.
- Develop new alloys and materials using technology to meet the desired outcome and requests.
- Production efficiency is the key as the process of casting involves a large volume of fuel and energy consumption.
- Production control layers of application via sensors which will process the repeated steps and lower production costs.
- Recycling and reuse need to be incorporated.
- Pollution control by reducing and channelizing the air or water emissions.
Generally the technological research in casting is conducted by the casting companies in 3 domains:
- Materials technology – improvising the materials used in alloying with respect to the physical and chemical properties, propose standard methodologies, ensuring a clean melting procedure, faster processing.
- Manufacturing Technology – Low cost and rapid cooling techniques of molten metals, size and dimension capabilities identification.
- Environmental Technology – Reduce air and water emissions, design to reuse and recycle the molten fluids, usage of stable and nonreactive chemical substances.
Types – There are several types of casting process, depending on the materials used for the process and application area, they are mentioned as below:
- Strand Casting – Here the molten metal is poured onto an open based water cooled mold.
- Casting Ingots – Here the metal is bottom poured in a stationery mold with the help of vacuum steam degassing.
- Sand mold casting – Here the sand molds are required to have a higher degree of refraction to ascertain that they don’t disintegrate under the influence of high temperature of the molten metal.
- Shell mold casting – It uses a sand and resin mixture to form a metal shell.
- Centrifugal casting – This process involves usage of a metal die.
Consult the pioneer casting manufacturers India for best quality and completely chemically treated casting materials.