Düsseldorf, 21-04-08 

Precision Casting – an Economical Solution for Complex Components

In addition to its wide range of alloys and materials which hardly another production technology can offer, precision casting is distinguished by the diversity of its methods. Next to the conventional method, which uses wax patterns and ceramic shell moulds on high-output production systems, a multitude of advanced rapid prototyping and rapid manufacturing technologies are used. These patternless manufacturing processes open up new applications in short production runs that used to be impossible to realise economically.

Whenever small batches of prototype castings are needed in a hurry, the quick cast process comes to the fore in which lost wax moulds are made without tools by stereolithography. The thermojet injection process may similarly be used to make complex lost-wax moulds in another tool-less process. Further alternatives include patterns and moulds made by laser sintering and other methods for use as lost-wax moulds and mould patterns that are generated indirectly within a tool. These methods permit producing relatively large batches economically in pilot production. All these processes are designed to enable castings to be produced quickly, economically, and flexibly in small batches of up to 50.

Precision castings are captivating because of the smoothness and homogeneity of their surface, their outstanding dimensional accuracy, and the freedom of design they offer. Today, precision castings are being made in weights ranging from a few grams to more than 100 kilograms. These castings are capable of surviving even extreme conditions such as those prevailing in aerospace applications. The portfolio of materials includes virtually all metallic substances that are used industrially, from noble metals via copper, titanium, and aluminium alloys to high-alloy steel grades and so-called super-alloys.

A special brochure published by the Zentrale für Gussverwendung summarises the potential of these versatile precision castings. It is available from the ZGV in Düsseldorf (zgv@bdguss.de) at a price of 12 Euros.

 

The subjects dealt with in previous ZGV information brochures include

• Austenitic Cast Iron Features Properties for Extreme Applications
• Welding of Castings – an Overview
• High-tech Castings Mirror the Dynamic Development of Wind Power Generation
• Cast Iron with Lamellar Graphite – still the most Frequently Used Cast Iron Material
• Cast Cylinder Heads and Crankcases Offer Versatile Solutions for the Cars of Today and Tomorrow
• High-alloy Casting Materials for Special Applications in the Pump Industry World
• Steel Castings for Buildings all over the World
• What to know about Cast iron with spheroidal graphite
• Versatile Non-destructive Tests for Castings
• Black Malleable Cast Iron – Strong and Tough
• Visual Determination of the Surface Quality of Castings by Reference Samples Graphite
• New Studies of the Bending-fatigue Behaviour of Cast Iron with Spheroidal Graphite