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Die casting
Aluminum Die Casting

Continuous casting
Main article: Continuous casting
Continuous casting is a refinement of the casting process for the continuous, high-volume production of metal sections with a constant cross-section. Molten metal is poured into an open-ended, water-cooled copper mold, which allows a 'skin' of solid metal to form over the still-liquid centre. The strand, as it is now called, is withdrawn from the mold and passed into a chamber of rollers and water sprays; the rollers support the thin skin of the strand while the sprays remove heat from the strand, gradually solidifying the strand from the outside in. After solidification, predetermined lengths of the strand are cut off by either mechanical shears or travelling oxyacetylene torches and transferred to further forming processes, or to a stockpile. Cast sizes can range from strip (a few millimetres thick by about five metres wide) to billets (90 to 160 mm square) to slabs (1.25 m wide by 230 mm thick). Sometimes, the strand may undergo an initial hot rolling process before being cut.

Continuous casting is used due to the lower costs associated with continuous production of a standard product, and also increases the quality of the final product. Metals such as steel, copper and aluminium are continuously cast, with steel being the metal with the greatest tonnages cast using this method.

Aluminum sand casting Spin casting, also known as centrifugal rubber mold casting (CRMC), is a method of utilizing centrifugal force to produce castings from a rubber mold. Typically, a disc-shaped mold is spun along its central axis at a set speed. The casting material, usually molten metal or liquid thermoset plastic is then poured in through an opening at the top-center of the mold. The filled mold then continues to spin as the metal solidifies or the thermoset plastic sets. Aluminum gravity casting Glass casting is the process in which "cast glass" objects, either functional or artistic, are produced by allowing molten glass to solidify in a mould, (a process called casting). This technique has been used since the Egyptian period. Modern cast glass is formed by a variety of processes such as kiln casting, or casting into sand, graphite or metal moulds. Investment Casting Spin casting, also known as centrifugal rubber mold casting (CRMC), is a method of utilizing centrifugal force to produce castings from a rubber mold. Typically, a disc-shaped mold is spun along its central axis at a set speed. The casting material, usually molten metal or liquid thermoset plastic is then poured in through an opening at the top-center of the mold. The filled mold then continues to spin as the metal solidifies or the thermoset plastic sets. aluminum casting process Sand casting aluminum alloy casting

Full-mold casting
Main article: Full-mold casting
Full-mold casting is an evaporative-pattern casting process which is a combination of sand casting and lost-foam casting. It uses a expanded polystyrene foam pattern which is then surrounded by sand, much like sand casting. The metal is then poured directly into the mold, which vaporizes the foam upon contact.

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Centrifugal casting
Main article: Centrifugal casting
Centrifugal casting is both gravity- and pressure-independent since it creates its own force feed using a temporary sand mold held in a spinning chamber at up to 900 N. Lead time varies with the application. Semi- and true-centrifugal processing permit 30-50 pieces/hr-mold to be produced, with a practical limit for batch processing of approximately 9000 kg total mass with a typical per-item limit of 2.3-4.5 kg.

Industrially, the centrifugal casting of railway wheels was an early application of the method developed by German industrial company Krupp and this capability enabled the rapid growth of the enterprise.

Small art pieces such as jewelry are often cast by this method using the lost wax process, as the forces enable the rather viscous liquid metals to flow through very small passages and into fine details such as leaves and petals. This effect is similar to the benefits from vacuum casting, also applied to jewelry casting.

prototype aluminum casting

Full-mold casting
Main article: Full-mold casting
Full-mold casting is an evaporative-pattern casting process which is a combination of sand casting and lost-foam casting. It uses a expanded polystyrene foam pattern which is then surrounded by sand, much like sand casting. The metal is then poured directly into the mold, which vaporizes the foam upon contact.

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