Types of new casting methods in the casting industry

As one of the oldest and most fundamental manufacturing processes in the industry, the casting industry plays an unparalleled role in shaping metal parts and manufacturing industrial tools. With the passage of time and technological advancements, traditional casting methods have given way to modern techniques that have not only improved the quality of manufactured parts, but also reduced production costs and time. Methods such as precision casting, semi-solid casting, and 3D printing casting have shown significant developments in this field.

Leading companies such as Khorshid Alyazh Tehran, by utilizing advanced technologies and focusing on providing quality services, play a key role in the development of these processes. These innovations have enabled the casting industry to meet the growing needs of modern industries such as automotive, aerospace, and energy. This article examines a variety of modern casting methods and analyzes their effects on the advancement of the casting industry.

What is cast iron casting?
Cast iron casting is a process in which molten iron is poured into molds to produce parts with desired shapes after cooling. Cast iron, as an alloy of iron containing 2 to 4 percent carbon and amounts of silicon, manganese, phosphorus, and sulfur, has unique mechanical and physical properties. These properties include high strength, wear resistance, and vibration absorption, which has made it one of the most widely used materials in the casting industry.

Reasons for the popularity of cast iron casting
Cast iron casting is popular in various industries, including automotive, machinery, pipe manufacturing, and construction industries, for several reasons. The unique properties of this alloy and its production process have made cast iron one of the main materials used in the production of industrial parts.

Wear resistance: Cast iron, especially gray and white types, is very resistant to wear and is considered ideal for applications such as the manufacture of parts subject to friction or impact.

Vibration absorption: Gray cast iron has an excellent ability to absorb vibrations, which makes it a suitable option for the production of machinery components and industrial bases.

High strength: Ductile iron (non-breakable) in addition to high strength, has good toughness and can withstand severe mechanical stresses.

Low production cost

The raw materials for the production of cast iron, such as iron and carbon, are relatively cheap and abundantly available.
Casting cast iron does not require complex and expensive equipment, and the sand molds used for it are also recyclable.
Lower operating costs, especially compared to more advanced alloys such as stainless steel or aluminum, make cast iron an economical material.

Ability to produce parts with complex shapes
Cast iron casting allows the production of parts with complex geometries and precise details. This feature has led various industries to use it to produce parts such as engine blocks, housings and fittings.

Variety in types of cast iron and wide applications
Cast irons are produced in different types (gray, ductile, white and malleable), each of which has its own properties and meets the needs of various industries.

For example, gray cast iron is used to manufacture parts with medium strength and high resistance to vibrations, and ductile cast iron is used for applications under heavy loads.

Easy machinability
Cast iron, especially gray types, has high machinability due to its graphite structure. This feature allows manufacturers to machine and modify parts with high precision and low cost.

Durability and Longevity
Parts made with cast iron have a long lifespan due to their good resistance to corrosion and wear. This feature makes cast iron an ideal choice for the production of industrial and construction equipment.

Disadvantages of cast iron casting
Fragility: Cast iron, especially gray and white varieties, is sensitive and brittle to tensile stresses and impacts.
High weight: The high density of cast iron makes it less suitable for applications that require light weight.
Susceptibility to thermal cracking: Sudden changes in temperature can lead to cracking in cast iron.
Lower surface quality: Cast iron parts often require polishing and machining to improve surface quality.
Casting defects: Possibility of gas voids, shrinkage, and other defects in the casting process.
Limited corrosion resistance: Ordinary cast iron corrodes over time in humid or acidic environments.
Limitations on complex designs: It is difficult to produce parts with thin walls or special designs.

What is sand casting?
Sand casting is a manufacturing process in the foundry industry in which molten metals are poured into sand molds to be shaped into desired parts after cooling. This method is one of the simplest and most cost-effective techniques in casting and is widely used in various industries due to its flexibility and ability to produce parts with complex dimensions and shapes.

Why is sand casting popular?

Low cost: The materials used in molding, such as sand and adhesive, are inexpensive and recyclable.

Flexibility: This method can be used to produce small and large parts of varying complexity.

Usability for a variety of metals: A variety of metals such as steel, aluminum, cast iron, and bronze can be cast in this process.

Disadvantages of sand casting
The final surface of the part may not be as smooth as parts produced by other methods such as casting.

Limitations in the dimensional accuracy of the parts.

The need for further processing (such as machining) after casting to improve surface quality and dimensions.

Final Words
Cast iron casting, as one of the main production processes in the industry, despite some disadvantages, still has a special place due to its advantages such as economic cost, high resistance and wide application. With the advancement of technology and the use of modern methods in design and production, it has become possible to improve the quality and reduce the limitations of this process. Utilizing up-to-date expertise and knowledge, such as what is done in companies such as Sahand Azarian, can pave the way for further development of this industry and respond to the diverse needs of different industries.