Shell Mold Casting

Our foundry in Zhejiang does shell mold casting for steel and aluminum. The resin sand mold enables complex geometries to be cast. We typically manufacture medium size parts require high accuracy such as gear housings, heat exchanger, connecting rods, and lever arms.

Shell Mold Injection Forming

Bead Blast

Cleaning

CNC Machining

Our Quality Guarantee Policy:
1. We take full responsibility for product quality.
2. First of all, we will do everything we can to only ship quality products to customers.
3. If a quality issues is identified, we with either replace them or fully refund the customer.

http://www.china-casting.org/

Vacuum Casting - China Casting Factory

Vacuum Casting uses a plastic film to cover sand surface and use vacuum to shape sand. It produces casting parts with better surface and dimensional accuracy. It is a greener method than traditional casting.

Our factory in Jiangsu China can cast steel or s.g. iron, from weight 10Kg to 3000kg. Please see the pictures below for samples of products.

Balance Weight for Folk Lift

Cast Steel Gear Box

Cast Steel Bolster

Cast Steel Universal Joints

Production Line for Vacuum Foaming:

Vaccum Casting Process Flow:
(1) Mold
(2) Heat up film
(3) Film covering and shaping
(4) Sand box
(5) Shaking and firming
(6) Close mold and pump vacuum
(7) Open mold and film is now on surface of sand
(8) Close Mold and Casting
(9) Open mold and clean off sand

http://www.china-casting.org

Green Sand Casting - China Sourcing

Caster green sand casting foundry in China uses green sand casting to more advanced binding processes to manufacture a wide variety of products for many different industries. These green sand casting parts are high quality and very cost effective. Green sand casting still remains one of the more popular methods for producing inexpensive, ductile iron repeatable castings with significant cast-in features. Because green sand casting or ductile gray iron casting process typically requires a large amount of labor, we are able to utilize our low cost structures in China, and provide a low cost final product, lower than almost any other green sand casting manufacturer. We are also able to offer finished machining and other secondary operations for your gray iron casting products in China for little additional cost.

Green Sand Casting

Green sand molds are composed of a particulate or granular material, typically sand, which is held together with a binder such as a mixture of clay and water. These molds may be manufactured rapidly for simple molds in an automated mold making plant. Its currently the most widely used of all sand casting methods, Green sand refers to the fact that water is added to activate the clay binder.

The green sand moulding process requires sand, clay and water to be mixed together to form a mould material that can be compacted around a pattern to produce a mould. Water develops the bonding characteristics of the clay, which binds the sand together, when used in its moist condition it is referred to as green. The green sand process can be used to produce castings in both iron ,aluminium as well as copper based metals. The process allows 90% to 95% reclamation of material and so provides a low cost form of production.
Various high quality castings are made of gray iron, ductile iron, aluminum, steel, brass etc. Quality control checks are performed throughout the casting process form screening the raw material for stability the concentration of alloy and melted by the electric furnace.

Features:
The sand-mold casting is adaptable to a very wide range of alloys, shapes, sizes, and production quantities. Hollow shapes can be produced in these castings through the use of cores. Sand-mold casting is by far the most common casting process used in industry;

Option for Green Sand Casting:
Green sand-mold casting involves mixing sand with a suitable clay binder (usually a bentonite clay) and other additives, and packing the sand mixture tightly around a pattern that is constructed from the part design. After extracting the pattern from the sand mold, a cavity is left behind that corresponds to the shape of the pattern. Next, molten metal is poured into this cavity and solidifies into a cast replica of the desired part. After the casting cools, the sand is readily removed from the casting and may be reclaimed for further use.

The green sand casting process provides a quality affordable solution for repeatable metal products with cast-in details and features. Please be sure to contact Cypress Industries for your die casting, green sand casting, closed die forgings, turnings and powdered metal low-cost manufacturing needs in China as well.


http://www.china-casting.org/green_sand_casting.html

Ductile Iron Casting - China Sourcing

The ductile iron casting has a clear advantage over malleable iron for applications where low solidification shrinkage is needed or where the section is too thick to permit uniform solidification as white iron.
Ductile iron, also known as ductile cast iron, nodular cast iron, spheroidal graphite iron, spherulitic graphite cast iron and SG iron.
While most varieties of cast iron are brittle, ductile iron is much more flexible and elastic, due to its nodular graphite inclusions.
Ductile iron is specifically useful in many automotive components, where strength needs surpass that of aluminum but do not necessarily require steel. Other major industrial applications include off-highway diesel trucks, class 8 trucks, agricultural tractors, and oil well pumps.

Ductile Iron Casting

To help realise the benefits of Caster in your manufacture, we would be pleased to explore any design opportunities with you. We can advise on all aspects of engineering with Caster including: alloy selection, foundry practice, dimensional stability and machining. We can discuss potential applications and perform material and cost analyses to help you justify selection of Caster for your products. We also invite you to visit our operations where we can demonstrate the process and our ISO9001:2000 credentials.

Laboratory & Testing facilities:
Spectrometer : ARL (Swiss) make with ARL net facility. 29 elements analysing capacity
Image analyser : With camera attached to the microscope.
UTM : 40 Tons capacity Fine make Universal Testing Machine for Tensile strength, Yield strength and Elongation.
Hardness tester : 3000 KGs Blue Start make Brinell Hardness Testing machine.
Sand testing : All the necessary sand testing equipments.
Wet lab : Full fledged wet lab for chemical analysis.

Quality Control:
We are maintaining the following documentation systems to assure quality.
Metal Chemistry Register
Mechanical testing Log Book
Dimensional inspection Log Book

Test Certificates:
We are conducting & providing the following certificates to the customer for every batch supply. Chemical test certificate
Physical / Mechanical test certificate.

Traceability:
The Quality Team supervises the Q.A / Q.C aspects along the entire process system by identifying and associating with Quality Circles. We ensure 100% tractability for the produce.

Occupational Health & Safety:
We, as an organization committed to Occupational Health & Safety of the workers and shop floor staff ensure strict adherence to body protective wears and covers for moving parts. The workers are constantly educated upon the importance of health & safety through displays and safety tips.

Contact Caster Treatments today to find out more about our comprehensive Austempered Ductile Iron services including ductile iron casting, bright annealing, salt quenching and gray iron casting.

http://www.china-casting.org

Aluminum Casting

Our aluminum casting range of products includes aluminum pressure die casting, aluminum gravity die casting, aluminum sand casting.
Aluminum investment castings from our China foundries directly compete with aluminum die castings. However, aluminum investment castings (lost wax casting) with the use of soluble core technology can allow for internal geometry that cannot be created in die casting due to molding core constraints.
Typically, aluminum investment castings will be more expensive than die casting, however the tooling costs for investment casting will be less expensive than die casting. In general lower volume parts are more suited for investment casting than die casting. Die casting is more automated than investment casting therefore reducing piece part costs.
Aluminum castings are typically used for weight reduction due to the fact that aluminum is stronger than steel on a pound for pound basis. This makes them suitable for any application requiring weight reduction such as the marine, automotive, aerospace and many other industries, its favored for being light weight and durable...

Aluminum Casting

Below is some more information on aluminum castings and alloys:
Typical uses for aluminum castings include engine parts, components and casings for the automotive and aerospace industries, brackets, electronic housings, light aircraft components, gear box casings and many other applications.
High strength with lightweight applications.
Cast aluminum alloys with strengths into the mild steel properties.
Prototype thru production runs.
Cast in all three molding processes: permanent mold, green sand and no-bake.
CAD computer files accepted.
Engineering assistance available.
Finishing options: heat treat, machining, paint/powder coat, chem treat, assemblies.

A foundry may be a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the steel in a mold, and getting clear of the mold material or casting right after the steel has solidified since it cools. Essentially the most widespread metals dealt with are aluminum and cast iron. However, other metals, along the lines of bronze, steel, magnesium, copper, tin, and zinc, are also used to develop castings in foundries.

http://www.china-casting.org/aluminum_die_casting.html

Metal Casting

The process of metal casting involves melting metals at high temperatures and using molds to then shape the metal into new items. It requires specialized equipment, knowledge, and some creativity. While metal casting is used on an Industrial level as the process cuts cost and proves to be highly efficient, many individuals participate in metal casting as a hobby and in artistic endeavors. Its a great way to build hard to find pieces for models, restoration projects, and even just small replacement parts needed for common household items.

Metal Casting

The actual casting process in metal casting has several forms, the most popular being sand casting. Sand casting involves creating a mold from sand which can be created at home, and then pouring the liquid metal into the mold. Afterwards, the metal is allowed to air dry and the mold is removed. This type of casting proves to be the most economical, but other types of casting can provide fuller detail and higher quality results.

Our metal casting process provides the ability to produce cast metal parts from a CAD file significantly faster and less expensively than traditional prototype casting methods. The process involves printing molds and cores on a 3D printer directly from digital data, eliminating the pattern and core box production step in the traditional sand casting process. Metal is then poured into the 3D printed molds. The technology allows you to prototype parts in metal that were previously cost and time prohibitive.

Advantages:
1. Extremely fast turnaround from CAD file to prototype metal part.
2. Ability to print complex molds and cores.
3. In-house mold making capabilities for product manufacturers.
4. Simple metal pouring process for foundries.

Process:
Printing molds and cores directly from digital data eliminates the pattern and core box production step used in traditional sand-casting processes. Metal is poured directly into the 3D printed molds enabling you to prototype parts in metal that are too costly or time consuming to produce using traditional methods.
Direct casting material can also be used to create sand casting molds for non-ferrous metals. This material is a blend of foundry sand, plaster, and other additives that have been combined to provide strong molds with good surface finish. It is designed to withstand the heat required to cast non-ferrous metals.

http://www.china-casting.org

Iron Casting

Description of Iron Casting:
Cast iron is derived from pig iron, and while it usually refers to gray iron, it also identifies a large group of ferrous alloys which solidify with a eutectic. The colour of a fractured surface can be used to identify an alloy. White cast iron is named after its white surface when fractured, due to its carbide impurities which allow cracks to pass straight through. Grey cast iron is named after its grey fractured surface, which occurs because the graphitic flakes deflect a passing crack and initiate countless new cracks as the material breaks.

Iron Casting

The iron casting is an alloy of iron and carbon in which the carbon is in excess of the amount that can be retained in solid solution in austenite at the eutectic temperature, In addition, silicon, manganese, sulphur and phosphorus are contained in varying amounts.

Iron casting are a family of ferrous metals with a wide range of properties produced by being cast into shape as opposed by being formed,other elements are used to control specific properties, cast irons have a wide range of mechanical properties which make them suitable for use in engineering components. The wide spread use of cast iron is as a result of its low cost and versatile properties.

Service:
1. Transfer known foundry technology into member operations.
2. Develop new technical knowledge or processes for use by the members.
3. Assist members in solving specific foundry problems in a consulting capacity.
4. Develop programs which will serve to educate technical and operating personnel employed by the members.
5. Function as an extension of each member's staff when dealing with customer problems.

Casting Materials:http://www.china-casting.org/materials.html