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Treating Molten Metal to Reduce Refractory Erosion

Treating Molten Metal to Reduce Refractory Erosion

Refractory erosion in iron melting is seldom attributable to mechanical wear. Erosion generally is the aftermath of slag’s chemical attack – chemical reactions between slag and refractory – producing reaction byproducts that enter the slag. The overall effect is refractory’s effective protection layer, the thickness of the refractory lining, is continually eaten away, eventually leading […]

Investment Casting (or) Lost Wax Method

Investment Casting (or) Lost Wax Method

The investment casting is a wax duplicate of the desired casting created to be invested into a “Ceramic Slurry”. The slurry-covered investment can be dipped into alternating coatings of sand and slurry until a suitable thickness of the shell is achieved that can hold the molten metal after the investment is burnt out. The “Burn-Out” […]

What is Sand Casting?

What is Sand Casting?

Sand Casting is a solidification process. In the casting process, sand is used to build a mould, following which liquid metal is poured into the mould to form a component. Therefore, the microstructure can be finely tuned, such as grain structure, phase transformations and precipitation. However, defects such as shrinkage porosity, cracks and segregation are […]

The Future of Investment Casting is Up in the Air

The Future of Investment Casting is Up in the Air

The investment casting process draws a lot of attention because of its high-value products, but the technologies involved in the process are quite impressive in their own ways. Now a pilot-scale melting system is offering some promise for increasing the volumes and range of alloys for those high-value products. The FastCast concept developed by ALD […]

Die Casting

Die Casting

The die casting process uses steel dies into which metal is forced under pressure through a runner and gate to fill the dies. The pressure (70 to 5000 kg/cm2) is maintained while the casting solidifies after which the dies are separated, cores are withdrawn and the casting is ejected. Metals and alloys that are die […]

Finding Value in Pig Iron and Creating Value in Melting

Finding Value in Pig Iron and Creating Value in Melting

Making iron castings involves two main sub-processes, one that deals with preparation of liquid metal, with the right proportion of alloying elements dissolved into it; and another that converts this liquid back to solid in the shape and size defined by the molds. The cost of making a casting is determined primarily by the metallic […]

Die Casting 101: Learn More About its Process and Advantages

Die Casting 101: Learn More About its Process and Advantages

Have you ever wondered how intricate automobile parts like starter motor brackets, flywheel, solenoid valves, and the likes are produced? Or, perhaps, the massive machine and equipment parts? How about those Hot Wheels toy car collections that kids love? The answer: die casting. Die casting is an industrial manufacturing process that uses tool dies, which […]

History of aluminum die casting

History of aluminum die casting

Early in the nineteenth century, the printing industry used the first aluminum die casting component supplier machinery, which marked the beginning of die casting. The mobile product development at the time benefited from this technological advancement. Sturges received a patent in 1849 for creating the first compact hand-operated device intended for casting printing type. It […]

Selecting and using abrasives for metal fabrication and welding

Selecting and using abrasives for metal fabrication and welding

Selecting the right abrasive and using that abrasive correctly for metal fabrication applications and welding can make all the difference in maximizing productivity and minimizing cost. Still, with today’s tight deadlines, fabricators are tempted to use whatever abrasive is handy without considering which is the best one for the application. Some might even ignore some […]