Question

What is the advantage and disadvantage of expendable and non-expendable casting process

Answer 1

Pros and Cons of different types of Casting ProcessesThere are various types of casting processes, each with its own set of benefits and disadvantages. Below, you will find the different casting processes, each with its advantages, disadvantages and recommended application.Investment CastingAlso know as lost wax casting, investment casting is a process commonly applied in cases where both solid parts and complex, hollow coresare required.Advantages*.It is able to deliver close dimensionaltolerances.*.Both ferrous and non-ferrousmetals can be castedusing investment casting.*.It delivers a good as-cast finish.*.With investment casting, complex shapes, intricate core sections, finer details and thinner walls are possible.*.It offers a flexibility in design and is a useful process for casting alloys that are difficult to machine.Disadvantages*.Investment casting has a higher cost associated with it. In fact, it is more expensive than Sand Casting, Permanent Mold and the Plaster Casting process.*.When compared to other types of casting processes, investment casting needs a longerproduct-cycle time.*.There is a limitation on the size of parts that can be casted.The advantages of this casting process overshadow costs when permanent mold and sand casting cannot deliver the desired complexity needed. Costs are also reduced by thequality surface finish investment casting delivers,reducing the cost of both machining and tooling.You can learn more about this process, metals that can be casted, precision, tolerances and more by visiting ourInvestment Castingpage.Sand CastingA process typically relying on silica-based materials, sand castings process involves finely ground, spherical grains tightly packed together into a smooth molding surface.Advantages*.This is the least expensive process when producing small quantities (normally less than 100) and also boasts with the least expensive tooling.*.With sand casting, manufacturers are able to cast verylarge parts.*.Bothferrousandnon-ferrous metalscan be casted using this process.*.A low post-casting tooling cost.Disadvantages*.Sand casting's dimensional accuracy is less than that delivered by other processes.*.This process requires largetolerances.*.The surface finish for ferrous casts delivered by this process usually exceeds 125 RMS.*.Castings produced with this proceed usually exceeds the calculated weight.The advantages of sand casting process are more beneficial in cases where strength to weight ratios allows for it. Yielding a lower degreeof accuracy, it does on the other hand offer low machining costs. For more information on this process, please visit ourSand Castingpage.Die CastingDie casting involves the molding of materials under high pressure, and consists ofCold-Chamber Conventional Die Casting,Hot-Chamber Conventional Die CastingandMulti-Slide Hot-Chamber Die Castingfor aluminum, brass, magnesium and zinc.Advantages*.Die casting is able to deliver parts that has a good dimensional tolerance.*.Parts produced using die casting require a minimal amount of post machining.*.This casting process also delivers an excellent part to part consistency, ideal for large production scales.*.It is a cost effective process when used for a high volume production run.*.This process is suitable formetalswith a relatively low melting point, such as aluminum, lead, magnesium, zinc and some copper alloys.Disadvantages*.This process is only an economically sound option for a large production quantity, as the tooling costs for die casting are expensive.*.In this process, it is difficult to guarantee minimum mechanical properties and is thus do not function as structural parts.*.This process is also not recommended for hydrostatic pressure applications.*.There is a limit on the size of parts that can be casted. It is a suitable process for castings of about up to 75 pounds.While it is an economically viable option for large production runs, die cast parts' mechanical properties cannot be assured, resulting in these parts not having a structural function. It is however a good process to opt for in cases where a large quantity of the part is needed, the parts produced will not have a structural function and in cases where parts will not be subjected to hydrostatic pressure.For further information on this process, please feel free to visit ourDie Castingpage.Permanent Mold CastingPermanent mold casting is a process used in which permanent molds consists of mold cavities, machined into metal die blocks and appropriate for repetitive use.Advantages*.This type of casting process is less expensive than die casting or investment casting.*.Casting delivered using this process are dense and pressure tight.*.Permanent mold casting is able to deliver a closer dimensionaltolerancethan sand casting is able to.*.The repeated use of molds are possible.*.It has a rapid production rate combined with alow scrap rate.Disadvantages*.This process is only able to castnon-ferrous metals.