Investment Casting Technical Support-Mechanical processes and technologies - Casting
    Casting is to meet certain requirements into the metal melting and pouring the liquid into the mold, the solidification by cooling, clearing the entire treatment by a book shape, size and performance of the casting process. Casting is the foundation of modern technology machinery manufacturing industry is one.
        Casting is a relatively early humans to grasp a metal heat processing, about 6,000 years. China about 1700 BC ~ before 1000 have been entered between the heyday of bronze casting, technology has reached a very high level. China's Shang weight 875 kg of Division home side Ding E, Warring States period of Marquis Yi of respect disk, the Western Han Dynasty of light transmission microscope, are representatives of ancient casting products.
        Most of the early casting of agricultural production, religious, and life, tools or appliances, art flavor. Then the casting process in parallel with the development of pottery technology, pottery by the great influence.
        China in 513 BC, the cast found out the world's oldest written records of cast iron - cast Jin Ding, weighing about 270 kg. Europe before and after the eighth century AD, began producing iron castings. The emergence of cast iron, to expand the application of the casting. For example, 15 to the 17th century, Germany, France and other countries have laid a lot of cast iron drinking water to residents for the pipeline. 18th century industrial revolution, steam engines, textile machines and the rise of railways and other industries, casting into a new period of industrial services for the large, casting technology began to have great development.
        Beginning of the 20th century, the development of fast casting, one important factor is the product of its advances in technology require a variety of mechanical and physical properties of cast better, while still has good machining properties; Another reason is the mechanical industry itself and other industries such as chemicals, instrumentation development, to the foundry industry to create a favorable material conditions. Such as the detection means of development, to ensure the casting quality improvement and stability, and to the casting development of the theory provided the conditions; electron microscope of the invention, to help people deep into the metal of the microscopic world, exploration of metal crystal mystery of metal solidification theory guide the casting.
        During this period, developed a large number of superior performance, rich variety of new casting of metal materials such as ductile iron, malleable cast iron can be welded, low carbon stainless steel, aluminum, copper, aluminum-silicon, aluminum-magnesium alloy, titanium-based, nickel-based alloy , and the invention of gray cast iron inoculation of new technology, so that casting a wider adaptability.
        After 50 years, there has been high pressure molding the wet sand, chemical hardening sand molding and core making, molding and other special vacuum casting, shot blasting and other new technology to make castings with high shape, dimensional accuracy and good surface finish, foundry working conditions and sanitation are also greatly improved.
        Since the 20th century's major advances in the casting industry, gray iron inoculation and chemical hardening sand molding process, two new special significance. These two inventions to break the continuation of traditional methods for thousands of years, to the casting process has opened up new areas to improve the competitiveness of the casting had a significant impact.
        Casting generally based modeling approach to the classification used is divided into ordinary and special casting sand casting. Sand casting, including wet sand, dry sand, three types of chemical hardening sand. Special Casting by modeling the material, can be divided into two categories: one with natural sand and gravel as the main form of mineral materials, such as investment casting, shell casting, vacuum casting, cement casting, solid casting, ceramics casting, etc.; a class of metal as the main mold material such as metal casting, centrifugal casting, continuous casting, pressure casting, low pressure casting.
        Casting process can be divided into three basic parts, namely, casting metal preparation, casting mold preparation and processing. Casting Metal casting is the production of metal castings for the cast, it is a metal element as the main ingredient, and adding other metals or non-metallic elements in the composition of the alloy, traditionally known as casting alloys, mainly iron, steel and ferrous alloy casting.
        Not just simply melted metal smelting, including smelting process, so that the metal poured into the mold, the temperature, chemical composition and purity aspects are in line with expectations. To this end, in the smelting process to conduct quality control checks for the purpose of the various tests, liquid metal target is reached only after a provision to allow the cast. Sometimes, in order to meet higher demand after the release of liquid metal in the furnace but also by processing, such as desulfurization, vacuum degassing, refining, processing, breeding or deterioration. Equipment commonly used in metal melting furnace, electric arc furnace, induction furnace, resistance furnace, reflective heaters.
        Different mold casting method to prepare different content. To the most widely used sand casting, for example, cast molding material preparation including the preparation and modeling made two core tasks. Sand casting used to form the core of a variety of manufacturing raw materials, such as casting sand, sand binders and other accessories, and prepared by them into the sand, core sand, paint and other materials collectively known as the modeling task of molding materials prepared in accordance with castings requirements, the nature of metal, select the appropriate raw sand, binders and accessories, then a certain percentage of them have certain properties mixed into the sand and core sand. Equipment commonly used in sand grinding wheel mixer, counter-flow mixer and the mixer blade groove. The latter is designed for mixing chemicals Sand design, continuous mixing, fast.
        Modeling manufacturing core is based on casting requirements modeling method in determining the good, ready to form the basis of the material carried. Casting accuracy and all the economic effects of the production process, depending on the working procedure. In many modern foundry, the model core are made to achieve a mechanized or automated. Commonly used core sand molding equipment made of high, medium and low pressure molding machine, throw sand machine, without me squeeze molding machines, core shooting machine, cold and hot-box machine.
        Cooling from the casting mold casting after being removed with the gate, riser and metal burrs Phi slit, sand casting sand casting still clinging, it must clean up process. Equipment for such work shot blasting machine, gate riser cutting machines. Sand casting off the sand clean-up is less a process of working conditions, so the choice modeling method, should be taken into account to create convenient conditions for cleaning off the sand. Some castings for special requirements, but also by post-casting processing, such as heat treatment, plastic surgery, anti-rust treatment, roughing, etc..
        Casting is a more economical method of rough shape, the shape of complex parts for more show its economy. Such as automotive engine cylinder blocks and heads, ship propellers and other fine works of art. Some difficulty cutting the parts, such as nickel-based alloy gas turbine parts can not be formed without casting method.
        In addition, the casting of the part size and weight to adapt to a wide range of metal types of almost unlimited; parts in general mechanical properties with the same time, with wear, corrosion resistance, shock-absorbing ability, it is the other metal forming methods such as forging , rolling, welding, punching, etc. can not do. Therefore, casting methods used in the machine manufacturing industry produced rough parts, the volume and tonnage, is the largest so far.
        Casting materials often use a variety of metals, coke, wood, plastic, gas and liquid fuels, modeling materials. Equipment requirements of various metal smelting furnace, a sand with a variety of sand mixer, a model built using a variety of core molding machine, core making machine, with clean sand casting off used machines, shot blasting machine and so on. Also for special foundry machinery and equipment, and many transportation and material handling equipment.
        Casting and other processes have different characteristics, mainly adaptability, needed materials and equipment and more, pollute the environment. Casting will produce dust, harmful gases and noise pollution on the environment than other mechanical manufacturing process to more serious measures are needed to control it.
        Casting product development trend is to ask the cast a better overall performance, higher accuracy, less margin and more smooth surface. In addition, energy requirements and the voice of the community to restore the natural environment is also increasing. To meet these requirements, the new cast alloy will be the development of new smelting technology and equipment will occur accordingly.
        Mechanization and automation of foundry production has improved, while the more flexible production to develop, to expand the volume and variety of different production flexibility. Conservation of energy and raw materials will be given priority in the development of new technologies, to produce less or no pollution to the new craft and new equipment will first be taken seriously. Quality control technology in all processes of detection and non-destructive testing, stress measurement, there would be a new development.
        Foundry workers in electronics and testing means continuous improvement of the conditions, the crystallization of metal solidification and the sand will be compacted so more in-depth exploration of the theory to study to improve casting performance and internal quality of an effective way. Casting robots and computer in the field of production and management applications, will also become increasingly widespread.

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