Wondering if metal casting is a science or an art? Casting foundries India say that metal casting is an art and a science. It is science for foundries as they need to deal with casting simulation software, robotics, automation, and other scientific approaches. It is an art because there are many invisible, uncontrollable factors playing role in regulating the output.
Manufacturers of metal castings have to control over production parameters to become reliable partners for consumers. Such control is required in non-ferrous foundries where limited process control techniques have been adopted. In this post, manufacturing units will share several difficulties included in aluminum casting practices.
There are several thermodynamic factors, foundry techniques, and physical metallurgy principles are involved in converting the metals into castings.
Aluminum and aluminum alloys
Aluminium is lately discovered and it is now widely used by people for making utensils, components, foils, etc.
Aluminium alloys have superb properties like-
- Good electrical and thermal conductivity
- Superior corrosion resistance
- Low density
- Easy fabrication and great recycling nature
- High strength development by alloying
These alloys are extremely purposeful for foundries that are making various components for automobiles, aerospace, electrical sector, and household appliances. Aluminum has a self-healing property that makes the material corrosion resistant.
Why it is a must job of foundry men to control moisture during aluminum casting process?
Dissociation of moisture during melting generates hydrogen and oxygen. This raises hydrogen absorption in the molten metal, which further promotes porosity issues in the casting. Pinhole porosity is a common problem in aluminum castings and this is the reason why foundry men need to control moisture during the process.
They should preheat the alloying elements and flux well to eliminate chances of moisture absorption. Charge selection is also critical. Clean aluminum alloy ingots and the one returned from foundry are best for use.
Challenges for the foundry industry
Science and technology keeps on evolving and since the innovation and development of newer materials have been growing along with science and technology, the applications of these products also have been growing.
Foundries have started replacing some metals with plastics and polymers due to reasons associated with costing, properties, fabrication, etc. Major challenges faced by foundries are-
- Insufficient technological resources
- Inappropriate production facilities
- Increasing prices of raw materials and fuel
- Stringent pollution control norms
- Uncertainty in business expansion
So, you can now imagine how tough it is for casting foundries India to survive in competition.