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DIFFERENT TYPES OF CASTING PROCESS:
1) Investment casting
2) Permanent mold casting
3) Centrifugal casting
4) Continuous casting
5) Sand casting
Investment casting
Investment casting (known as lost-wax casting in art) is a process that has been
practiced for thousands of years, with lost wax process being one of the oldest known
metal forming techniques. From 5000 years ago, when bees wax formed the pattern, to
todays high technology waxes, refractory materials and specialist alloys, the castings
ensure high quality components are produced with the key benefits of accuracy,
repeatability, versatility and integrity.
Investment casting derives its name from the fact that the pattern is invested, or
surrounded, with a refractory material. The wax patterns require extreme care for they
are not strong enough to withstand forces encountered during the mold making. One
advantage of investment casting it that the wax can be reused.
The process is suitable for repeatable production of net shape components, from
a variety of different metals and high performance alloys. Although generally used for
small castings, this process has been used to produce complete aircraft door frames,
with steel castings of up to 300 kg and aluminum castings of up to 30 kg. Compared to
other casting processes such as die casting or sand casting it can be an expensive
process, however the components that can be produced using investment casting can
incorporate intricate contours, and in most cases the components are cast near net
shape, so requiring little or no rework once cast.
Permanent mold casting
Permanent mold casting (typically for non-ferrous metals) requires a set-up time
on the order of weeks to prepare a steel tool, after which production rates of 5-50
pieces/hr-mold are achieved with an upper mass limit of 9 kg per iron alloy item (cf., up
to 135 kg for many nonferrous metal parts) and a lower limit of about 0.1 kg. Steel
cavities are coated with a refractory wash of acetylene soot before processing to allow
easy removal of the workpiece and promote longer tool life. Permanent molds have a
limited life before wearing out. Worn molds require either refinishing or replacement.
Cast parts from a permanent mold generally show 20% increase in tensile strength and
30% increase in elongation as compared to the products of sand casting.
The only necessary input is the coating applied regularly. Typically, permanent mold
casting is used in forming iron, aluminum, magnesium, and copper based alloys. The
process is highly automated.
Sub-types of permanent mold casting
1. Gravity Die Casting.
2. Low pressure die casting.(LPDC)
3. High pressure die casting.(PDC)

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
(90 g). 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.
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 millimeters 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.
Sand casting
Sand casting is one of the most popular and simplest types of casting that has
been used for centuries. Sand casting allows for smaller batches to be made compared
to permanent mold casting and a very reasonable cost. Not only does this method allow
for manufacturers to create products for a good cost there are other benefits to sand
casting such as there are very little size operations. From castings that fit in the palm of
your hand to train beds (one casting can create the entire bed for one rail car) it can be
done with sand casting. Sand casting also allows for most metals to be cast depending
in the the type of sand used for the molds.
Sand casting requires a lead time of days for production at high output rates (120 pieces/hr-mold), and is unsurpassed for large-part production. Green (moist) sand
has almost no part weight limit, whereas dry sand has a practical part mass limit of
2300-2700 kg. Minimum part weight ranges from 0.075-0.1 kg. The sand is bonded
together using clays (as in green sand) or chemical binders, or polymerized oils (such
as motor oil.) Sand in most operations can be recycled many times and requires little
additional input.

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DIFFERENT TYPES OF CASTING PROCESS:

3. High pressure die casting.(PDC)

Continuous casting is a refinement of the casting process for the continuous,

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