Gravity Sand Casting

Gravity sand casting is a process mainly used in the casting of metals with high melting points such as cast iron and cast steel.
The sand is molded to make the mould, and the casting methods of the gating system and riser need to be appropriately designed in order to control filling defects (gas hole, sand erosion, etc), solidification defects (macro shrinkage cavity, microporosity).

Large ingot casting is a process, which uses a permanent metal mould. Only when the star crack usually created in the center of the ingot is effectively controlled, can cracks occurring during post-processes such as extrusion be prevented and the mechanical properties of the final product be guaranteed.

A process usually applied to high-functional special steel products, which have complex shapes, investment casting often has a very big gating system.
Only when the gating system is designed appropriately by effectively controlling the shrinkage cavity, can productivity be enhanced.

As it is a rapid cooling solidification process, planar flow casting must take into consideration glassification and the viscosity of the undercooled liquid metal.
The temperature and pressure of the melt fed into the nozzle are the main process variables and only when the cooling power and rotating speed of the roll, the gap between the roll / nozzle etc., are appropriately designed is it possible to obtain
a sound shape or properties of the manufactured strip.

A process generally applied to non-ferrous alloys(Al, Mg, Zn), high pressure die casting is a method where the melt is fed into the mould by pressurization to cast metals at high-speed. Defects such as gas holes, cold shut, and inclusion entrapment are taken care of by appropriately controlling the shape of the runner, the cross section of the ingate, the position and size of the overflow, etc. Problems arising from the overheat of the mould, which in return is a result of repetitive operation, such as shrinkage defects, coarse structure, and delay in cycle time can be solved by installing an appropriate cooling line and consistently maintaining the temperature of the mould.

It is a casting process where small pressure(air or inactive gas) is applied to the melt surface inside a sealed vessel and the melt is pushed up in the opposite direction of gravity, feeding it into the mould installed in the upper area of the stalk.
The more the product weighs and complex the shape becomes, the higher the mould temperature becomes in order to maintain directional solidification and make smooth the melt flow. As a result, more time is required till the end of the solidification, lengthening the cycle and reducing productivity. The higher the mould temperature gets, the rougher the product structure becomes and the less the mechanical property. Thus, in order to obtain a sound product, it is important to properly set the size and location of the gate as well as pressurization and channel location.