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GMP Metal Casting Service

Metal Casting is one of the services that GMP offered  you and your customized metal fastening and stamping parts.

  • Metal Casting
  • Process of metal casting
  • Metal Casting
  • Process of metal casting

The Process of Metal Casting

Pattern creation and mold preparation: The first step is to create the final metal object, then create a mold by packing a refractory material around the pattern.

Pattern removal: After the mold has been created, the pattern is removed, leaving behind a cavity in the mold.

Molten metal preparation: The desired metal alloy is heated in a furnace until it reaches its melting point.

Pouring: The molten metal is carefully poured into the mold cavity through a pouring channel called a sprue.

Solidification: As the molten metal fills the mold, it begins to cool and solidify.

Cooling and removal: After solidification, the metal casting is allowed to cool further until it reaches a temperature at which it can be safely handled. The mold is then removed or broken apart to extract the solidified casting.

Finishing: The casting may undergo additional finishing processes to remove any excess material to achieve the desired surface finish.

The Feature of Metal Casting

The Feature of Metal Casting

Metal casting is a manufacturing process that involves pouring molten metal into a mold and allowing it to solidify to obtain a desired shape. It is a versatile and widely used method for producing complex metal parts. And it has some key features:

  • Versatility: Metal casting can be used to produce a wide range of shapes and sizes, from intricate and detailed components to large and heavy industrial parts. It allows for the production of complex geometries that may be difficult or expensive to achieve through other manufacturing processes.
  • Design Flexibility: Casting offers significant design freedom, allowing for the creation of parts with intricate features, undercuts, thin walls, and internal cavities. This flexibility enables engineers to optimize the design for functionality, performance, and cost-effectiveness.
  • Recycling and Sustainability: Metal casting is a highly recyclable process. Excess material or defective parts can be easily remelted and reused, reducing waste and contributing to sustainability efforts.
  • Heat Resistance: Many cast metals and alloys exhibit excellent heat resistance, making them suitable for applications that involve high temperatures or thermal cycling.

Applications of Metal Casting

Metal casting finds numerous applications across various industries due to its versatility and ability to produce complex shapes. Some common applicationsb of Metal Casting is as following:

  • Automotive Industry: Metal casting is extensively used in the automotive industry for manufacturing engine blocks, cylinder heads, transmission components, suspension parts, and other critical components. Casting allows for the production of intricate shapes and reduces the overall weight of the vehicle while maintaining strength and durability.
  • Aerospace Industry: The aerospace sector relies on metal casting for the production of turbine blades, engine casings, structural components, and other parts that require high strength-to-weight ratios. Casting enables the creation of complex geometries and intricate cooling passages, contributing to the performance and efficiency of aerospace systems.
  • Energy and Power Generation: Casting is employed in the energy and power generation sector for producing turbine components, boiler parts, heat exchangers, and other critical equipment. The ability to withstand high temperatures and pressures, along with excellent mechanical properties, makes cast metal parts suitable for power plants and renewable energy systems.
  • Medical Equipment: Metal casting is used in the production of medical equipment and devices such as orthopedic implants, surgical instruments, prosthetics, and dental components. Casting allows for the creation of patient-specific designs and complex shapes for better functionality and patient comfort.
The Applications of Metal Casting
Different Types of Metal Casting

Different Types of Metal Casting

Metal Casting can be classified based on several factors such as molding material, mold complexity, mold reusability, solidification method and casting method:

  • Continuous Casting: Continuous casting is a method primarily used for producing long, continuous sections of metal with a constant cross-section. It involves continuously pouring molten metal into a water-cooled mold, which solidifies the outer shell. The partially solidified metal is continuously withdrawn from the bottom of the mold while being further cooled and solidified. Continuous casting is employed for the production of metal bars, rods, strips, and other long products.
  • Centrifugal Casting: Centrifugal casting utilizes centrifugal force to distribute molten metal evenly within a spinning mold. As the mold rotates, the denser impurities are forced toward the center, while the molten metal is pushed towards the outer regions, resulting in a defect-free casting with improved material properties. Centrifugal casting is commonly used for cylindrical or tubular parts, such as pipes, cylinders, and rings.
  • Permanent Mold Casting: Permanent mold casting, also referred to as gravity die casting, is a process similar to die casting but with a reusable mold made of metal, such as steel or cast iron. The molten metal is poured into the mold under gravity without the use of high pressure. The metal solidifies, and the mold is opened to extract the cast part. Permanent mold casting is commonly used for producing parts with better dimensional accuracy and surface finish than sand casting, making it suitable for applications requiring tighter tolerances.
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