Metal Casting

Specialize in metal casting for decades

Our company has provided the highest quality custom metal castings services since 2003. We are providing customers with the highest level of quality parts and services.

Our metal casting services are designed to meet the exact needs of our customers, and our team is committed to providing this value with precision engineering and innovative tooling capabilities.

Our experience in manufacturing parts for various industries has enabled us to focus on meeting specialized requirements with precision and excellence.

We can provide customised prototyping services for any finished part designs or pre-production prototypes leading up to finished parts production and eventual assembly of whole products. Throughout the process, we ensure our customers’ expectations are exceeded by delivering customized solutions for each industry need.

With our dedication to high-quality service delivery and customer satisfaction, we guarantee complete access to innovative resources that will ensure satisfactory results in your product development process.

From the simple machining of pre-production prototypes through comprehensive finished part production and assembly, Taiyuan Forging focus on comprehensive customer support every step of the way. So whether you’re looking for standard products or unique customized solutions, Taiyuan Forging has you covered!

What are metal castings?

Metal casting is the process of pouring hot liquid metal into a mold containing a hollow cutout or cavity of the desired finished shape. The liquid metal then solidifies and is ejected from the mold, releasing the final product.

Metal castings come in various shapes and sizes and can be used for countless products and applications in many industries. First, molten metal is poured into a mold, which is then cooled to form the desired shape. Some of the most popular casting processes involve sand molds, plastic molds, investment casting, and even permanent molds.

Sand molds are common for large parts that can withstand pressure from the mold during cooling. Plastic molds provide more detail than sand but cannot take as much pressure.

Investment casting involves forming complex components by encasing wax forms within a ceramic material that is then heated until the wax melts away and leaves behind a cavity to hold the casting alloy.

Permanent molds allow for faster production of consistent castings with reliable quality control. As a result, metal castings have been used in everything from building construction to engineering design to art pieces.

Basic steps in the casting process

Casting is a common manufacturing process used to create parts from liquid materials, and several basic steps are involved.


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Core Making

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Melting and pouring

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Patternmaking is the first step in the casting process and involves creating a model, or "pattern," of the desired casting from wax, wood, metal, sand, or other materials. Before patternmaking can begin, a drawing must be prepared that details the exact shape and measurements required for the finished product. Once this blueprint is complete, patterns are created to replicate it exactly. This includes anyone unique features of cutouts or holes that need to be machined into the final cast. After being made, patterns are typically inspected and tested to ensure they comply with any necessary quality standards before moving on to the next stage of production. Coremaking follows patternmaking as part of the casting process and involves creating cores out of sand that will be used to form hollow portions inside of casts. Cores can range greatly in complexity and size depending on their intended use and should be accurately machined based on requirements specified by drawings. The next step in casting is molding; once all patterns and cores have been created they are combined with box molds into a large assembly called "the flask." This flask contains both reusable components (e.g., patterns) and consumable components (e.g., core boxes). Lastly, molten metal is poured into this setup, where it fills up its assigned areas completely before being cooled down and removed from molds for finishing as required for its intended use. All together, these steps make up a basic overview of how a Casting Process works.

Types of Metal Casting Processes

Investment Casting​

Investment casting is a versatile manufacturing process that uses molten metal to form precise parts, often with complex geometries. Investment casting begins with creating a positive replica of the desired part, known as a wax pattern.

The pattern is molded into a ceramic slurry and allowed to dry completely, forming an enclosed shell that is heated until the wax melts away. Molten metal is poured into the void left by the melted wax and the mold is allowed to cool until the part solidifies.

After it has cooled, the mold is broken and the part can be removed for further finishing. This method produces highly precise parts with repeatable accuracy and minimal waste, yet with shorter lead times than traditional fabrication processes like machining or forging.

Its precision, affordability, and flexibility invest casting a popular choice for medical components, aerospace parts, art pieces, musical instruments, household items, automotive parts – even custom jewelry.

Permanent Mold Casting

Permanent mold casting is a metal casting process that utilizes reusable molds, also known as dies. It is used for producing various parts with complex geometries, including pins, rods, brackets, and other components.

It differs from sand casting in that the same mold can be reused many times between replacements, increasing efficiency while reducing cost. The permanent molds are made from cast iron or steel and require machining to create the desired die shape.

The molten metal is poured into the cavity and allowed to solidify before it is removed. This process works best with non-ferrous metals such as aluminum or copper due to their low melting point, but ferrous alloys can also be cast using certain precautions when dealing with higher temperatures.

Once complete, the casting may require minimal finishing work like brushing, polishing, or coating before being ready for use – making it an efficient way of producing parts at scale without sacrificing quality and detail.

Permanent mold casting can produce parts with smooth surfaces and tight tolerances making it one of the most popular casting processes for small-to-medium production runs today.

Due to its economic benefits and versatility, it is used in various industries, from automotive to plumbing applications. Regardless of the industry, this age-old process is still invaluable for creating large quantities of custom parts at relatively short lead times.


Die Casting

Die casting is a manufacturing process that uses molds to form metal parts. The process begins with placing the desired shape, typically made out of metal or other hard materials, into a particular machine called the die-casting machine.

Molten metal is then forced into the mold through an injection nozzle at very high pressure. This creates pressure and heats evenly distributed throughout the mold, allowing the metal to form evenly over every part of the object.

The objects formed by die casting can be intricate and complex and include many shapes and textures. Die casting allows detailed objects to be reproduced relatively quickly compared to other methods, such as forging or machining. It also has superior material strength and durability due to its uniform grain structure caused by the consistent application of pressure when it is produced.

Additionally, die-casted items are usually lighter than those created through other processes, reducing production costs in certain applications where weight is critical.

Die Casting has many advantages over traditional manufacturing processes. Still, some drawbacks exist, such as inconsistent detail accuracy, a limited number of alloys that can be used, and high energy consumption during production.

Despite these drawbacks, die-casted products are still widely utilized across multiple industries because they offer excellent design flexibility while being cost-effective at scale.

Sand Casting

Sand Casting is a process used to create metal parts from molten metal that is poured into a sand mold and allowed to cool. The strength of the mold material, typically packed sand, holds its shape as the molten metal is poured and cooled, creating a detailed part with exact dimensions and a smooth finish.

The process has existed since ancient times and is still widely used in many industrial applications. Sand Casting begins with preparing the pattern, which determines the size, shape, depth, and other details of the part being created. The pattern is then placed against the so-called ‘drag’ where damp sand is carefully packed at high pressures before solidifying and forming a mold.

As soon as it becomes hard enough, the drag is moved away from the pattern with care not to break the newly formed mold. Lastly, molten metal or alloy is then heated up to an optimal temperature for pouring into a gating system attached to the casted surface of the mold. Once poured, it will take several hours to solidify and finally be ready for removal from its cavity before undergoing any finishing processes like grinding or coating applications.

Sand Casting may be time-consuming but ultimately allows talented artisans to craft precision parts from intricate patterns that otherwise could not have been made from any other method. It also produces extremely durable parts free of flashing or burrs that can be customized for various productions offering innovative design possibilities each time.

Advantages of the Metal Casting Process

  • Casting has a low cost for medium to high volumes compared to other manufacturing processes.
  • Mandatory components can be manufactured in one piece
  • Metal casting can create complex shapes
  • The metal casting process is mainly free from the limitations of casting size, thickness, and shape
  • Features such as internal cavities and hollow profiles can be easily cast
  • Metal castings have a certain degree of dimensional accuracy
  • Almost any material can be melted into a liquid alloy and used for casting

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