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Metal Casting Processes
Metal Casting Processes
Sand
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ADV: basically any metal or shape since you can have cores, weight isnt an issue and its p cheap as far as these processes go
LIMITS: Requires post processing (finishing), wide tolerances, cant make thin shapes
honestly, making patterns and moulds are a whole big thing by itself!!
Plaster Mould
low porosity!! great for accuracy,
aka PRECISION CASTING so you know it has nice surface finish. detail, dimensions.
made with like plaster of paris, gypsum, talc/silica and water. the slurry is poured over a pattern. forms halves
non ferrous metals only. not great for mass produced parts, fiddly i guess. takes ages to make a mould.
Shell Mould
pattern is made of a metal, and the pattern is coated in sand or silicone so that the casting metal doesnt stick to the pattern. the sand is resined and hardens and BOOM u got dat shell happnin'
shell is thin like 5-10mm, smol grains must so its mad permeable and wow that gas, so much more gas than a thiqq mould situation. good ventilation is a must.
since its still like sand and stuff, you can make small complicated shapes like gear housings, connecting rods.
ADV: dimensional accuracy, nice surfaces, good for mass production
LIMITS: smol parts onli, large fixed cost bc the patterns and equipment are $$
Evaporative Pattern
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ADV: most metals can be cast, complexity of parts, no size limit! LIMITS: low strength of mould, not good for low volume production (bc of the die)
no parting lines, cores, risers required to get a complicated shape
Investment
wax pattern coated in ceramic slurry to make the mould, wax melted out, metal poured in. ceramic smashed. normally you connect heaps of patterns together on a tree
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Expendable Mould, Permanent Pattern
Expendable Mould, Expendable Pattern