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Casting Process

Silica Sol Casting

Silica Sol Investment Casting is a form of investment casting. The process is very similar except that the investment mould is made from silica sol zircon sand mixed with refractory powder. Silica sol zircon sand is exceptionally fine-grained (10-20 Microns) and can be mixed to a slurry with very low viscosity when creating the mould. The result is a casting method that delivers dimensionally accurate castings with excellent as-cast surface finishes. Crucially, the silica sol zircon mould can withstand temperatures up to 2000°C, making them very useful when casting high temperature alloy steels and stainless steels.

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Process	Silica sol Casting (Green Wax)
Mold	General Aluminum Mold & Steel Mold
Mold Material	Middle Temperature Wax
Mold Shell	Silica sol, Mullite Sand, Zircon Sand
Technology Characteristics	Suitable for producing small parts. Better precision. Better surface roughness. Can large extent reduce machining.
Tolerance Range	CT5 to CT6
Single Weight	0.01kgs to 30kgs
Surface Roughness	RA6.3
Casting Material Type	Carbon Steel, Alloy Steel, Stainless Steel, Ductile Iron.
Common Material Specification	GB, ASTM,SAE,AISI,DIN,BS,JIS,NF,EN,AAR,ISO
Product application field	Automobile, Engineering Machinery, Railway, Marine, Agricultural Machinery, Mining and other industrial fields
Advantages& disadvantages	Environmental protection, surface roughness is better than RA6.3, but the price is 1.0-2.0 yuan /KG higher than sodium silicate

Lost Foam Casting

Lost foam casting is a type of evaporative pattern casting. This method is quite similar to investment casting which uses wax instead of foam in the pattern making process. The foam pattern was first used in metalworking in 1958. Although this mold casting technique is not as popular as other methods such as sand mold casting or permanent casting, it maintains outstanding advantages, especially in casting complicated and precise molds.

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Process	Lost Foam Casting
Pattern	General Aluminum mould & Steel mold
Mould Material	STMMA Copolymer Resin
Mould Shell	Fireproof Coating
Technology Characteristics	Instead of the traditional sand Mold casting. Without the core-making process. Better dimensional accuracy.
Tolerance Range	CT8 to CT9
Single Weight	0.2kgs to 200kgs
Surface Roughness	RA12.5
Casting Material Type	Grey Iron and Ductile Iron, Alloy Steel
Common Material Specification	GB, ASTM,SAE,AISI,DIN,BS,JIS,NF,EN,AAR,ISO
Product application field	Automobile, Engineering Machinery, Railway, Marine, Agricultural Machinery, Mining and other industrial fields

Water Glass Casting

Water glass Investment casting is very similar to investment casting (i.e. the lost wax method), but is particularly suited to larger castings and is cheaper to produce. The process provides a far superior surface finish and dimensional precision to that achieved through sand casting, and more complex shapes can be achieved. In addition to steels, it is possible to cast alternative materials such as iron and SG iron using this method.

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Process	Water glass Casting
Mold	General Aluminum Mold & Steel Mold
Mold Material	Low Temperature Wax
Mold Shell	Sodium Silicate, Quartz Sand
Technology Characteristics	Suitable for complicated structures. Reduced machining allowance. Decrease production cost.
Tolerance Range	CT7 to CT9
Single Weight	0.5kgs to 200kgs
Surface Roughness	RA12.5
Casting Material Type	Carbon Steel, Alloy Steel, Grey Iron and Ductile Iron
Common Material Specification	GB, ASTM,SAE,AISI,DIN,BS,JIS,NF,EN,AAR,ISO
Product application field	Automobile, Engineering Machinery, Railway, Marine, Agricultural Machinery, Mining and other industrial fields

Shell Mold Casting

Shell mold casting is a metal casting process similar to sand casting, in that molten metal is poured into an expendable mold. However, in shell mold casting, the mold is a thin-walled shell created from applying a sand-resin mixture around a pattern. The pattern, a metal piece in the shape of the desired part, is reused to form multiple shell molds. A reusable pattern allows for higher production rates, while the disposable molds enable complex geometries to be cast. Shell mold casting requires the use of a metal pattern, oven, sand-resin mixture, dump box, and molten metal.

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Process	Shell Mold casting
Pattern	Steel mold
Mould Shell	Phenolic resin coated sand
Technology Characteristics	Suitable for mass production, and simple structure parts.
Tolerance Range	CT7 to CT8
Single Weight	0.2KGS to 50KGS
Surface Roughness	RA12.5
Casting Material Type	Carbon Steel, Alloy Steel, Stainless Steel, Grey Iron and Ductile Iron
Common Material Specification	GB, ASTM,SAE,AISI,DIN,BS,JIS,NF,EN,AAR,ISO
Product application field	Automobile, Engineering Machinery, Railway, Marine, Agricultural Machinery, Mining and other industrial fields

Lost Wax Investment Casting

Lost wax casting builds a mold around a sacrificial wax model. After the mold investment is set, the wax is melted out and forms a cavity where the metal or glass flows in. Using this method of casting captures fine details in both metal and glass. This ancient method has been used since 3000 B.C. to visually capture the stories of ancient cultures and religions throughout history.

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Process	Lost wax investment casting
Pattern	General Aluminum mould & Steel mold
Mould Material	Low Temperature Wax
Mould Shell	（the first two layers）Silica sol+Zircon Sand，(other layers ）Sodium Silicate
Technology Characteristics	Suitable for small products with high surface quality requirements
Tolerance Range	CT5-CT7
Single Weight	Below 2KGS
Surface Roughness	RA6.3
Casting Material Type	Carbon Steel, Alloy Steel, Grey Iron and Ductile Iron
Common Material Specification	GB, ASTM,SAE,AISI,DIN,BS,JIS,NF,EN,AAR,ISO
Product application field	automobile, Engineering Machinery, Railway, Marine, Agricultural Machinery, Mining and other industrial fields
Advantages& disadvantages	Environmental protection, surface roughness is better than RA6.3, but the price is 1.0-2.0 yuan /KG higher than sodium silicate