Casting is a cost-effective method for creating components with extremely complex geometries. It involves the melting and casting of materials with using furnaces and specific melting practices.

1. What are the Casting Processes?

  • Cast component design: This involves designing the component that is to be cast, taking into account factors like material properties and the intended use of the component.
  • Mold/die layout and manufacturing: It involves creating the layout for the mold or die and then manufacturing it. The mold or die is the form into which the molten material will be poured to create the cast component.
  • Melting of the metal and metallurgical conditioning of the melt: In this step, the metal is melted and conditioned metallurgically to ensure it has the right properties for casting.
  • Filling of the die cavity: This involves pouring the molten metal into the die or mold cavity.
  • Solidification of the melt in the die/mold: After the molten metal is poured into the mold, it needs to solidify. This process must be controlled to ensure the quality and integrity of the final cast component.
  • Shakeout/part removal: Once the part is solidified, it is to be removed from the mold/die cavity. This step changes the cooling rate and restrictions in shrinkage and affects the tolerances and residual stresses.
  • Fettling and part post-casting treatments : This is the last step where runner
    and gating systems are removed

2. Which metals are used in casting?

  1. Iron:
    • Gray Cast Iron: Known for its excellent machinability and vibration damping properties. Commonly used in engine blocks, machine frames, and cookware.
    • Ductile Iron (Nodular Cast Iron): Offers good tensile strength and ductility. Used in automotive applications, pipes, and heavy-duty gears.
    • White Iron: Hard and brittle, often used in wear-resistant applications like liners for cement mixers and slurry pumps.
  1. Steel:
    • Carbon Steel: Versatile and economical, used for structural components, automotive parts, and machinery.
    • Alloy Steel: Contains additional elements like chromium, nickel, and molybdenum for enhanced properties. Used in high-strength applications like aerospace and automotive parts.
  1. Aluminium and Alloys:
    • Commonly used due to its light weight and corrosion resistance. Ideal for aerospace, automotive, and consumer goods.
  1. Copper:
    • Offers excellent electrical and thermal conductivity. Used in electrical components, heat exchangers, and plumbing fixtures.

3. Advantages of Casting

  • Ability to produce very large parts.
  • Capability to form complex shapes.
  • Availability of many material options, including alloy steel, carbon steel, cast iron, stainless steel, aluminium, copper, magnesium, nickel, lead, tin, titanium, and zinc.
  • Low tooling and equipment costs.
  • Possibility to recycle scrap.
  • Potential for short lead times.

4. What are the applications of casting?

          1.Automotive Industry:

    • Engine parts (blocks, cylinder heads, manifolds)
    • Transmission components
    • Structural components (chassis, wheels)

          2.Construction and Infrastructure:

    • Pipes and fittings
    • Structural components (beams, frames)
    • Decorative elements (gates, fences)

          3.Machinery and Heavy Equipment:

    • Gears and pulleys
    • Large machine parts (frames, housings)
    • Hydraulic components

          4.Energy Sector:

    • Wind turbine components
    • Parts for hydroelectric power plants
    • Components for nuclear and fossil fuel power plants

          5.Rail Industry:

    • Railway Components
    • Track and infrastructure parts

          6.Defence:

    • Weapon components
    • Vehicle parts (tanks, armored vehicles)
    • Naval ship components

Novelty Steel offers various casted products complemented with machining operation.

Competed Projects

Products

Steel Structures

Plant Engineering Fabrications

Bulk Material Handling Structures 

Steel Buildings

Steel Silos

Hoppers & Chutes

Steel Trusses

Mezzanines & Stairs

Steel Tanks

Services

Laser Cutting 

Metal Bending

Plate Rolling

Machining

Welding

Painting