CASTING PROCESS
DESCRIPTION
METALS
SIZE RANGE
TOLERANCES 0-3" = 0.03" per in. + 0.005" per in. for each additional in. Across parting line add 0.020" to small castings, 0.090" to large castings 0-3" = 0.03" per in. + 0.005" per in. for each additional in. Across parting line add 0.020" to small castings, 0.090" to large castings Ferrous: +/-0.008" per in. up to 3" add 0.003" per in. over 3" Non-Ferrous: Add 0.005-0.010" per in. across parting lines, under 1" = +/-0.004" 1-3" = +/-0.010" 3-6" = +/-0.013" 6-12" = +/-0.016" 12-20" = +/-0.020"
AVERAGE RELATIVE RELATIVE TOOLING COST FOR COST FOR COST HIGH QTY LOW QTY
SURFACE FINISH Ferrous: 420-900 RMS Aluminum: 175-350 RMS Copper Base: 300-560 RMS Ferrous: 420-900 RMS Aluminum: 175-350 RMS Copper Base: 300-560 RMS
MINIMUM DRAFT REQUIRED
MINIMUM SECTION THICKNESS Ferrous: 0.250-0.375" Non-Ferrous: 0.125-0.250"
EASE OF CASTING COMPLEX DESIGNS
EASE OF CHANGING DESIGN
COMMENTS
GREEN SAND
Process that mixes raw sand, clay and water, which is then compacted around a pattern to create a mold. Most common type of molding, suitable for any production volume, and typically a low-cost option.
Most Castable Metals
All sizes per foundry capabilities
Low
Low
Low
1-5 degrees
Fair to Good
Best
Most widely used casting process for both small and large production runs.
NO BAKE / AIRSET
Molding method utilizing raw sand combined with resins and binder to create a hard mold capable of improved surface nishes. Excellent for lower-volume parts where superior dimensional stability is required.
Most Castable Metals
All sizes per foundry capabilities
Low
Low
Low
3-5 degrees
Ferrous: 0.250-0.375" Non-Ferrous: 0.125-0.250"
Fair to Good
Best
Widely used casting process for both small and large production runs.
SHELL
Resin-coated sand, typically of a smaller grain size than green sand, which is applied to a heated pattern that activates the resin to create a hard-shell mold. Exceptional surface nishes can be achieved with reduced machine stock and/or draft.
Most Castable Metals
Typical max mold area = 3000 in2
Medium
Medium
Medium
Ferrous: 200-350 RMS Aluminum: 75-150 RMS Copper Base: 150-200 RMS
0.5-2 degrees
Ferrous: 0.125" Non-Ferrous: 0.080"
Good
Fair
Used for production of fairly small parts for which closer tolerances and improved surface nishes are required than are obtainable from sand castings. Widely used in core production.
Casting process in which wax replicas are coated with a slurry mix of ceramic refractory and sand, allowed to dry, and then heated to extract the wax, leaving INVESTMENT behind a near-net-shape cavity. Capable of creating shapes that are not possible by any other molding method, particularly for small or intricate components. Widely used to eliminate additional machining expense.
Most Castable Metals
0.1 to 100 lbs
+/-0.005" per in. up to 3" add 0.002" per in. over 3"
Medium
High
Medium
60-120 RMS
0-1 degrees
Carbon Steel: 0.090" Stainless Steel: 0.125" Aluminum: 0.030" Copper Base: 0.030"
Best
Fair
Used for precision castings, particularly for complex designs.
LOST FOAM
Can be utilized in two different methods; The rst method is similar to investment, in which a polystyrene replica is coated with ceramic refractory and then molded in sand. The second method consists of foam patterns that are molded into a media similar to no bake or airset. In either method, molten metal is poured directly into the sand mold and evaporates the foam during the casting process, creating a part with no draft or parting lines.
Most Castable Metals
Up to several hundred pounds
0-3" = 0.03" per in. + 0.005" per in. for each additional in. Across parting line add 0.020" to small castings, 0.090" to large castings
Low
High
Low
Per type of foam used
None
Ferrous: 0.250-0.375" Non-Ferrous: 0.125-0.250"
Good
Good
Widely used for prototypes and low usage parts. In some cases patterns can be used more than once.
PERMANENT MOLD
Reusable metal tooling that can be used to create repeatable dimensional accuracy, typically used for decorative or ornamental products made from nonferrous materials.
Aluminum & Copper Base
All sizes per foundry capabilities; Aluminum = 0.5 to 100 lbs.
Aluminum: +/-0.015" per in. up to 1" add 0.002" per in. over 1" Across parting line add 0.010" to small castings, 0.030" to large castings 0.0015" per in. Not less than 0.002" on any one dimension. Across parting line add 0.010"
Medium
Medium
High
Aluminum: 125-200 RMS Copper Base: 175-225 RMS
Ferrous: 3-5 degrees Aluminum: 2-4 degrees Copper Base: 3-5 degrees
Ferrous: 0.187-0.250" Aluminum: 0.100-0.150" Copper Base: 0.100-0.150" Aluminum: 0.050" Small 0.080" Med Zinc & Mag.: 0.025" Small 0.040" Med
Fair
Poor
Used for moderate quantities of semiprecision castings. Normally less expensive than sand casting for 100's - 1000's of parts. Limited applicability for ferrous metals.
DIE CAST
Method in which molten metal is forced into a metal die under pressure. This process is suitable for repeatability of medium- to high-volume, intricate or close-tolerance parts.
Aluminum, Zinc, Magnesium, & Copper Base
Typical max mold area = 3 ft2
High
Low
High
20-90 RMS
Aluminum: 1-3 degrees Zinc & Mag: 0.5-2 degrees
Good
Poorest
Very widely used for high production of aluminum and zinc castings. An inexpensive way of obtaining precision parts.
CENTRIFUGAL
Process utilizing permanent tooling that is rotated horizontally or vertically while molten metal is introduced, typically used to manufacture pipe or other cylindrical products.
Most Castable Metals
OD 2 to 50 in; Length & wall thickness per foundry capabilities
OD = 0.1" Small Dia ID = 0.03-0.06"
None
Low
Medium
250-500 RMS
None
Per foundry capabilities
Not Practical
Good
Used for round tubular or cylindrical castings. ID will likely require machining due to impurities. Excellent casting soundness.
V-PROCESS
Dry sand molding method that uses a vacuum to hold a membrane on the surface of the pattern, which is then backlled with sand. Advantages are exceptional surface nish and tighter dimensional control than most conventional sand casting processes.
Most Castable Metals
All sizes per foundry capabilities
+/-0.010" per in. up to 1" add 0.002" per in. over 1" Across parting line add 0.020" max
Medium
Medium
High
125-250 RMS
None
0.090-0.125"
Good
Good
Unlimited pattern life. Used for medium to high volumes.
Dominion Metallurgical, Inc. 2/19/2010
