Full-mould casting – cost-effective production of even complicated components
Full-mould casting is a modern casting process for the production of components. Even complex functional parts with cavities can be created inexpensively. Possible are full-mould castings made od iron or cast steel. After casting, the intact and thus functional condition is tested in strict internal test procedures. Only after successful testing, the components are delivered to the customers, such as the automotive industry, mechanical engineering or other industries.
Description of full-mould casting
Full-mould casting is a special production process. Hereby, glowing metal melts of iron or steel are poured into a full mould. In contrast to other casting processes, there is no need to use a binder to set the sand around the full model. This protects the environment and saves costs for the preparation of the castings.
Features of full-mould castings
Full-mould castings are made of iron or cast steel, depending on the molten metal used. They all are characterized by a seamless intact form woth only a small amount of post-processing effort. Complicated components with or without cavities are implemented particularly accurately by the full-mould casting. The resistance of full-mould castings is important, for example, for the high loads on components in the automotive industry or in machines and plants. The production of PS-E models is possible in automated production. Thus. Large quantities can be implemented in a short time at low costs.
Production of components through full-mould casting
Prior to the start of the production, a one-to-one workpiece is produced with the help of a PS-E (styrofoam). Depending on the shape, it may also be several parts that are assembled before casting. A sizing (protective layer) is pulled over the cast-ready model. Now it is placed in a container, which is filled with moulding sand. The PS-E styrofoam model gasifies when casting. The resulting gas is sucked through the molding sand. During the casting process, there is no direct contact between the sand and the melt. The sand can then be used again for new shapes. At the end of the full-mould casting, the workpiece remains in the mould until it is solidified. Then it will be taken out and adapted to the other specifications according to the order description.
Silbitz is your contact person for full-mould casting
Full-mould casting easily simplifies the manufacture of even complex components for vehicles, machines and plants. The preparation can be automated cost-effectively in medium quantities. In addition, the process is one of the environmentally friendly manufacturing processes. For example, the molding sand remains free of binders and can thus be reused several times.
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