the different types of aerospace castings - technical die casting
Different types of aerospace cast iron are usually formed with molds in discrete parts, or by continuous cross-cutting of a general shape continuous castingsection.
Mold casting has been successfully applied to a process for centuries, which involves pouring molten steel into a fixed-shape cavity to produce aerospace technology castings.
There are six common methods: sand casting-
As the name implies, the process involves the use of sand as a means of dealing with the cooling of molten iron into the required form.
First define the shape in the sand with a wooden pattern, then remove it, and then fill the cavity with molten iron.
This is a cheap way for limited volume applications.
Similar to sand casting, but using a permanent mold made of water
Cold Steel mold.
This is an expensive method that is best suited for high volume applications. Die castings-
A process similar to plastic injection molding, which involves pressurizing the molten metal into the mold.
This is expensive and requires a lot of parts to amortize the high cost of the mold. Shell castings-
This process involves making the shell or shell of the pattern first (or actual part)
, Split it to take it out, reassemble the part, and finally put the shell into the sand.
When the molten metal is poured into the shell, the sand supports the shell.
After cooling, remove the part by breaking the shell to reveal the finished part.
This process is labor intensive, but it is a good process for complex parts produced in small batches.
The results produced by this casting process are similar to shell casting, but are aimed at larger castings.
Build a mold to form a wax pattern, then remove it, apply the ceramic material, heat it to remove the wax and put it in the sand.
Then pour the melted metal into the interior, let it cool, and then remove the ceramic housing.
This is the most commonly used method for the production of aerospace aluminum castings.
This process involves the production of parts by using a rotating drum with a mold as the inner diameter of the drum.
When the molten metal is poured into the interior, it rotates to form the desired part, and when cooled by the split mold, the Department branch is removed.
This is the most common form of pipe.
Continuous casting is a relatively new process developed completely after the Second World War.
As the name says, the process involves continuously pouring molten metal into water from the bottom of the Crucible
A cooled mold, forming a shell that allows it to be further processed on the production line.
This process essentially produces high-quality castings because the material is drawn from the bottom of the Crucible, away from the slag and other impurities floating on the surface.
It is also subjected to different cooling results, resulting in different crossover
Segmented material properties, the external area is usually composed of graphite structures that are thinner than the core to provide a comprehensive surface hardness and overall toughness.
Two forms of graphite, thin sheets are usually produced (
In gray iron)and nodules (
In cast iron).
The solubility limits of these forms involve many factors that are not easy to control or economical and need to be added, known as the incubation agent to be added, which forces the graphite out of the solution, and make it possible to control the size and shape of graphite particles.
The casting process requires careful consideration of the three parameters of the casting part, which usually determine the casting method selected.
These are the dimensions of the part, the required tolerances, and the surface finish.
Generally speaking, the larger the parts, the more expensive the tools and handling equipment are.
Processes that require hard tools such as die casting or investment casting are not used to produce large parts, while sand castings do not have this limitation.
The tradeoff here is the quality and surface finish of the part.
Larger parts may create internal cavities due to shrinkage, while sand castings do not have an improved surface finish provided by the hard working process.