Casting Processes http://www.wynndanzur.com/Casting%20Processes.

htm

2007 Wynndanzur.com

THE CASTING PROCESSES

_________________________________ by Wynn Danzur Marketing

Due to the Website's large size, and your equipment, this Section may take a few minutes to fully unload.

This Section is very large and designed as Educational Tool.

Not every Casting Process is listed, only the most commonly used.

If there is a topic of Interested NOT presented in the entire Website, please e-mail through the
webmaster, what it is you are looking for. The best efforts will be given to accommodate
requests for "Additional Sources," by return e-mail.

The Casting Processes that are explained, are done so in a format that only Introduces the
reader to that Casting Topic. It is the reader's responsibility to go beyond what this Website has
initiated.

If a reader requires further in depth information on a Casting Process, or topic, this information
can be obtained from the local Library, the Internet, AFS, and the Organizations supporting that
particular Casting Process.

the origin of Metal

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Castings ___________________
According to biblical records, Casting technology reaches back almost 5,500
years BC.

Gold, pure in nature, most likely caught Prehistoric man’s fancy…as he

probably hammered gold ornaments out of the gold nuggets he found.

Silver would have been treated similarly.

Mankind next found copper, because it appeared in the ash of his camp fires
from copper-bearing ore that he lined his fire pits with.

Man soon found that copper was harder than gold or silver.

Copper did not bend up when used.

So copper, found a ‘nitch’ in man’s early tools, and then marched it’s way into
Weaponry.

But, long, long before all this…man found clay.

He used clay and made pottery, now he had something to eat from. (
Kitchen-aide and the Dishwasher, would not come around for many more
years.)

Time passed ...

Then Man thought, "now…what else can I do with this clay mud stuff …" .

Early man thought about it, "I’ll use this pottery stuff, ( the first patterns ), to
shape my metal into bowls ".

Man had discovered the Casting Industry.

Castings
A casting, is the essential foundation of civilization. With it, man unlocked his
future, placing him on the path toward conquering his environment.

History tells us this happened in Mesopotamia, today's modern Iraq. The oldest
casting in existence today is believed to be a frog, cast in copper.

The frog’s complexity indicates that it was preceded by other simpler casting
efforts. Things went slow back then.

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Tin, came around in the 16th Century, but man used earth's ores for 4500 years
prior. The Chinese get the nod for iron castings around 1000 BC. India made
steel about 500 BC. Civilization in general, was casting brass by then, ( brass =
copper / plus zinc ) , which was many centuries before the Christian era.

All along this path all the techniques for …" CASTING AND MOLDING PROCESSES
" … were being discovered, and recorded into history.

All of these processes would be pictured forever in time through the labors of
early man.

Listings of the Casting Processes Groups

I. CONVENTIONAL - CASTING PROCESSES
II. PRECISION - CASTING PROCESSES
III. SPECIALIZED - CASTING PROCESSES

Broken down further:

The Individual Castings Processes / by their Groups

1. Conventional Castings Processes Groups are:

Sand Castings
Green Sand Casting
Flask-less molding
Dry Sand Molding
Sand Slinging
Shell Core Molding
Loam moldings, assorted processes

Click on the Process Group that interests you, and that will take you to the Location.

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2. Precision Casting Processes Groups are:

Investment Casting
Shaw Process
Replica Casting
Rubber Casting – Molding
Spin Casting
Permanent Molding Process
Die Casting
Powdered Metal Casting Process
Click on the Process Group that interests you, and that will take you to the Location.

3. Special Casting Processes Groups are:

Styro-foam molding
Special V-Process Casting
Centrifugal Castings
Continuous Casting
Slush Casting
NO-Bake Casting
Squeeze Process

Click on the Process Group that interests you, and that will take you to the Location.

***********************
Metal Casting Process
Application Chart
" What Casting Process do I need for my Casting Project ?"

Below is a simple Application Chart that lists the basic Casting Processes and

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then the type of Normal Casting Application work that best suits that Process.

You can use this chart and compare the project you have in mind to determine
a possible Casting Process.

Many Processes, can be used for the same project, the quantities needed, cost
per unit, tooling costs, are all factors in determining which process, is right one
for your project.

Casting Process Application Chart Details

Use this chart to compare the project you have in mind, in determining a possible Casting and
Molding Process.

* Navigation Guide: Click on the Process Group that interests you, and that will take you to the
Location.

The Application Chart

[Casting Process = the normal application expected ]

Sand Castings: everyday mechanical components, currently made as

fabrications, weld-a-ments, or off the shelf assembled parts.

Green Sand Castings: same as sand castings.

Permanent Molding: depending on the situations permanent molding can be

looked at as an alternate process for almost all sand casting ( green sand ),
and flask-less molding processes.

Investment Casting: dental appliances, jewelry, firearms, weapon systems,

engine parts, aircraft parts, anything that requires high definition, high details
and easily duplicated.

Powdered Metal Casting: motor hubs, gears, spacers, magnets, slides, blanks,
automotive, lawn and garden, hardware, air-movement, recreation,
agriculture, elevators, escalators

The V-Process: medical equipment, machine tools, testing stands and

equipment, specialty equipment, audio drivers, (speakers housings), aircraft,
automotive, agriculture

Die Casting: power tool bodies, handles, parts, triggers, housings, bases,
plumbing, hardware, agriculture, aircraft, rails, gates, caps, covers, tops,
bottoms

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Grey Iron Casting: pump housings, impellers, covers, caps, tops, bases,
plumbing, agriculture, hardware, sewer covers, gears, blanks, hubs, flywheels,
casings, housings

Flask-less Molding: this casting and molding process can replace sand, green
sand, and used with gray iron, whenever high volume, high out put,
economical, exact duplications are required

**********************************
Casting Processes
The Three Casting Process Groups

I. CONVENTIONAL - CASTING PROCESSES

II. PRECISION - CASTING PROCESSES
III. SPECIALIZED - CASTING PROCESSES

I. The CONVENTIONAL CASTING PROCESSES:

1A.) SAND CASTING ( also called, GREEN- SAND MOLDING ) – is the most
commonly used casting platform throughout the entire Casting Industry, World
Wide. Simply put, there is a top, a bottom, and a middle to a mold. The pattern,
or impression device, sits in the middle of the mold, and later is surrounded with
sand . These are the basic, universal casting components, which can be
applied to all casting processes.

The top and the bottom of the pieces of the mold form the flask. The flask
assembly, the top and bottom, "holds the whole thing together". The upper or
topmost section of the flask of the mold (flask) is called the cope, while the
bottom of the mold (flask) is called the drag. The impression device, in the
middle, is called the pattern. The sand around the pattern is called the, holding
medium. The mold maker uses the pattern to make the impression in the sand.

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He then sets the pattern aside. At that point, the molder closes the cope and
drag, forming the mold. What the mold maker wants is the void left from the
impression of the pattern, in middle of the sand, inside the mold. So, he fills that
void with a molten material.

Basic casting like this, is also called, "Green Sand Molding, or Green Sand
Casting". These are the most basic molding methods, currently used in today’s
casting practices, regardless of the metal alloy, or any molten - liquid material
being poured. Like was said in the Preface, Man has been casting things since
before Biblical times, using these very concepts.

All casting techniques employed in the rest of the Casting and Molding
Processes are in many ways, just like sand casting, or green sand molding. With
some thought and imagination, you can always see the cope and drag
principle of casting we already discussed. The different techniques or casting
and molding processes are used to achieve a desired end product, which has
a special need in the market place. This special need prompted man to
develop special processes.

Examples of usage would be: Air movement components ( fan blades), hubs,
shafts, tubes, rectangles, squares, holes, no holes, the list is endless.

1B.) GREY IRON CASTINGS – This process is very much like sand casting and green
sand casting processes. It can be done as flask-less molding. The difference being that the
molten material is gray iron.

Grey Iron is white iron to which 2% to 3% carbon has been added to reduce the
hardness and brittleness of iron. See GREY IRON in Glossary.

Examples of usage would be: pump bodies, housings, impellers, sewer covers,
gears, blanks, bases, pads, motor mounts etc.

2.) FLASKLESS, MOLDING – This process is a sand casting, or a green sand

molding variation, that has been automated for speed and high volume
out-put, of identical castings. Despite any misconceptions, a flask-less molding
does use flasks. The flasks, " holds the whole thing together ". A Flask must be
used on all sand molding for the containment of the sand, while the sand is
firmed about the pattern. In flask-less molding, in either a vertical or a
horizontal stance, a sand filled flask is rebuilt and used over and over, in this
totally mechanized, and automated sand molding process. In sand casting or

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green sand casting, a tight fitting, individual – most likely sand filled flask – is
used for each mold produced.

The Industry has sand molders, use machines named "Hunter" or "B&P", to
identify the makes and models of their flask-less molding equipment. The
benefits of these systems are very impressive … uniformity, high density molds,
high out put of products, elimination of mold shift, just to mention a few, all of
which drastically reduce labor expense.

Flask-less Molding provides a mold hardness that is consistent though out the
mold. The operator can adjust to different cope, drag heights and total
squeeze pressure to accommodate different mold densities and mold hardness
to meet the molding application. The operator can adjust the sand fill allowing
the adjustment for variations in each pattern. It is possible produce complex
molds and mold with deep pockets, which are difficult with traditional, normal
sand casting procedures

Rapid core setting, easy inspection of cores used, utilization of existing tooling,
high casting quality, reduced finishing time, quick pattern change, exceptional
mold to mold consistency, high productivity are some of the many reasons to
use flask-less molding.

Examples of usage would be: Any thing you can make in a sand mold, but you
want it made for high volume, high production type out lets.

To see an animation about how an automated molding machine operates, visit

the Hunter Automated Molding Corporation
link: http://www.hunterauto.com/seq/index.htm

3.) DRY SAND MOLDING – large components are very difficult to cast to exact
size and dimensions. Hence, some foundries use dry sand molds to produce
such parts. Dry sand molding is the green sand process modified by baking the
mold at prescribed temperature. Engine blocks, large gears, big housings,
construction parts, are examples of dry sand process candidates. Ferrous and
non-ferrous metals are cast in this method. The key to this process is the proper
baking time in relation to the binder and the moisture content. The other factors
are the size, weight, and mass, of the component being cast. Wynn Danzur can
explain the profitable advantages of this process to you. Some good examples
are, the great strength of the part cast, exactness in dimension, much smoother
finish, etc., but most important is how these processes will benefit your casting
jobs.

Examples of usage would be: engine blocks, transmission housings, big gear
boxes, etc.

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4.) SAND SLINGING – is the rapid process of mechanically filling the flasks with
sand. The sand is propelled into the flask, like a sling-shot. This yet, just another
method for compacting the sand into the cope and drag of the flask. Some
sand slingers are stationary, some portable, and are some moveable. The big
plus with this process, is the elimination of sand waste, which is the universal
sand foundry problem.

Examples of usage would be: large pump bodies, gear boxes, boat engine
blocks, gears, Large valve bodies, etc.

5.) STACK MOLDING – is another high production, sand casting, or green sand
molding process. The piston ring people know this method well. Simply
explained, the bottom of a given flask in a stack provides the cope of the flask
below, while the top, provides the drag of the next layer…"pan caked- casting
".

Examples of usage would be: piston rings

6.) DRY OR BAKED "SAND CORE" MOLDING – very intricate automotive and
agricultural castings are formed with this process. Accuracy, is the key word
here along with close tolerances. A binder is mixed with un-bonded sand, it is
then formed to the mold or pattern and baked. This is an expensive process,
that achieves high level accuracy, in all dimensions..) DRY OR BAKED "SAND
CORE" MOLDING – very intricate automotive and agricultural castings are
formed with this process. Accuracy, is the key word here along with close
tolerances. A binder is mixed with un-bonded sand, it is then formed to the
mold or pattern and baked. This is an expensive process, that achieves high
level accuracy, in all dimensions.

Examples of usage would be: engine blocks, transmission housings, gear

housings, pump housings etc.

7.) SHELL CORE MOLDS - are the earliest, most automated, and most rapid of
mold, and core making processes. This technique is also called the " C "
Process or, Croning. Found in Germany after WW II, from a patent issued to
Johannes C. A. Croning. The " C "Process uses a fluidized, harden-able sand –

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synthetic resin mixture to do shell molding and shell core making. Some big
advantages are closer tolerances, increased productivity, excellent casting
surface finishing, almost "as cast quality ". Wynn Danzur, can work with you to
determine how best this process may fit your operation. the earliest, most
automated, and most rapid of mold, and core making processes.

Examples of usage would be: engines valve heads, transmission cases, valve
bodies, etc.

8.) OTHER CONVENTIONAL PROCESSES - Loam Molds, Chamotte Molds, Compo

Molds, Cement-Bonded Molds, Floor and Pit Molds, Sweep Molds( like loam
molds), Open Sand Molds, Waterless Bonded Sand Molds, are some of the
lesser used, but also very important processes.

8.1) Oil Based Sand Casting - is very similar to regular sand casting and green
sand casting, but a oil based mixture of sand is employed, instead of earth and
sands and clays. This concept, provides Die Cast like finish, at a fraction of the
cost, because no expensive die casting tools are required. When long life span,
and high out put required for the application, a Die Casting is best option.

II. PRECISION CASTING PROCESSES

A.) INVESTMENT CASTING - or the "lost wax" process has been in use since the
construction of the first pyramid.
The Egyptians and Chinese used the process in their early history to make
statues and jewelry. The investment casting method was largely ignored as an
industrial process for the fabrication of parts until the demand for rapidly
finished parts during World War II created the need for near net-shape
components that could readily be put into their final form. Then new inorganic
high temperature ceramic mold binders were developed to industrialize the
process applications to include high strength and corrosion resistant materials
such as low to high carbon alloy steel, tool steel, stainless steel, and nickel and
cobalt base alloys. Aluminum and brass alloys are available also. It is a
process capable of producing intricate shapes weighing from a small fraction

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of an ounce up to forty pounds or more.

Make sure to visit Investment Casting in the Exploded Drawings, Exploded

Drawings .

Some examples of usage would be: dental appliances, jewelry, components

for the automotive industry, military weaponry, jet engines, aircraft structural
parts, machinery components, and many others.

Investment castings works this way:

A injection molded wax pattern is used for each part produced which is then
encased in multiple layers of ceramic material. The wax pattern is then
removed from the ceramic shell mold. The mold is fired in an oven and then
molten metal is poured into the cavities left by the evacuated wax pattern.
Upon cooling, the resulting precision castings are cleaned and subjected to
further processing such as heat treatment. At this point, many parts are in their
final form and are ready for use while others may require a small amount of
further processing such as machining before reaching their final form.

When properly applied, the advanced technology can offer complex near
net-shapes that reduce overall manufacturing costs by minimizing material
and labor inputs. Parts designs can be lighter in weight, more complex and are
available in a wider range of alloys than those offered by other processes.
Stronger materials, better surface finishes, thinner walls, difficult internal
configurations and closer tolerances than those available through alternate
processing techniques are some of the other advantages of the investment
casting process.

The word investment, in INVESTMENT CASTING, denotes the mechanical manner

of making a mold rather than the material used. This process employs a
three-dimensional pattern – using all three dimensions – to produce a one time
destructible mold into which molten metal will be poured. A very simple
example would be to pour wax into and egg shell, let it cool, then crack away
the shell. People, not especially versed in casting terms, on occasion associate
this process with financial matters.

A.1) Lost Foam Process - This Process is similar to "Lost Wax", better known as
Investment Casting, in that both the casting mediums are expended, either
melted or evaporated away, leaving the cast part.

Make sure to visit "Lost Foam" Casting Process in the Exploded Drawings, or
Views Sections.

A.2)Ceramic Mold Casting -

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Also known as `cope and drag investment casting'.

The basic process is:

1. A wood or metal pattern is placed in a flask and coated with a slurry of

zircon and fused silica combined with bonding agents.
2. The mold is removed, cleaned and baked. The shells may be used as
given, or they may have other materials, such as clay put on as backing
materials.
3. The molds are then used as normal.

This can make high temperature material parts.

B.) THE SHAW PROCESS – this is one of the best known of the INVESTMENT
CASTING variations. The chief difference is that a jelling agent is added to the
inside of the destructible mold …instead of cracking away the mold, it is
stripped away.

C.) REPLICA CASTING – can be made from any material that can be burned
away, burnt out, or incinerated …leaving a pattern chamber free of ash and
residue. Examples would be…plants, seedpods, insects, etc. This method is for
very intricate designs, costume jewelry, precious metal replica.

D.) RUBBER MOLDS – is made of silicone or vulcanized rubber. It is a form

containing the impression of an original mold. It is then filled with wax to
duplicate identical molds of the original. A slurry is dipped around the wax, the
wax burnt out and the molten metal poured into the void left by the burnt away
wax. A simple example would be a mouth piece for dental work.

E.) SPIN CASTING – this bridges the gap between die casting and sand casting
by incorporating the some of the important advantages of both of those
processes.

E.1) Centrifugal Casting - is another name for this same Process.

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Production of prototype castings, in high or low volumes, with low tooling costs
and short lead times, yielding die cast quality parts known for the close
tolerances.

How it all works:

" ...Imagine a star inside a circle both made of rubber. At the ends of the points
of the star are the patterns…the arms of the star are the sprues for the molten
material to flow out to the patterns. The circle is spun and the molten material is
poured into the center of the star… the spinning motion casts the part.

F.) PERMANENT MOLDING – is very much like sand casting, but no sand is used,
and there is no real impression device…just a metal vessel shaped to the
configuration of the part wanted, this is the impression device.

The vessel is closed, an molten metal is poured inside, there it is allowed to

cool and set up. Then the "cope and drag " are opened up and there is the
cast part.

In Permanent molding, just as the names states, the mold is permanent, in that
it is used over and over again, unlike a sand mold, that is re-made, after each
sand cast part, is produced.

Alloys suited for Permanent Molding both ferrous, and nonferrous. – is very
much like sand casting –but – no sand is used, and there is no real impression
device…just a metal vessel shaped to the configuration of the part wanted, this
is the impression device.

The vessel is closed, an molten metal is poured inside, there it is allowed to

cool and set up.

Then the "cope and drag " are opened up and there is the cast part. In
Permanent molding, just as the names states, the mold is permanent, in that it is
used over and over again, unlike a sand mold, that is re-made, after each
sand cast part, is produced.

Alloys suited for Permanent Molding both ferrous, and nonferrous.

Permanent Molding is also referred to as Gravity Die Casting.

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Advantages of Permanent molding over other processes are;

the molten metals cool more rapidly than sand, producing a sound dense
casting with superior mechanical properties, high degree of uniformity, high
degree of dimensional accuracy, less scrap castings, more machining
secondary operations can be " cast-out " of project – reducing overall costs, a
consistent quality finish.

All casting techniques employed in the rest of the Casting and Molding
Processes are in many ways, just like sand casting, or green sand molding.

With some thought and imagination, you can always see the cope and drag
principle of casting we already discussed.

The different techniques or casting and molding processes are used to achieve
a desired end product, which has a special need in the market place. This
special need prompted man to develop special processes.

Examples of usage would be: Permanent molding can replace just about all
sand casting applications, where the benefits listed above are desired.

G.) DIE CASTING – this process is for high volume, high detail, value added,
economy priced, cast parts.

A metal tool is built, and it is attached to a furnace of molten metal, this molten
metal is mechanically poured…injected into the metal mold, the mold cools
for a brief time, it opens the parts come out… the process repeats, over and
over and over. Advantage is very high production with great duplication, with
great tolerances.

An Aluminum Die Casting - is a process where molten aluminum alloy is

injected into a closed vessel called a casting die or mold, under high pressure
and at a controlled temperature.

The mold has sections which include the "cover" or hot side and the
"moveable" or the ejector side.

The die may also have additional moveable segments called slides or pulls
which are used to create features such as undercuts or holes which are parallel
to the parting line.

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Aluminum die casting molds operate in cold chamber die casting machines.

These machines run at the required temperatures and pressures to produce a

quality part to net-shape or near net-shape specifications.

Aluminum die castings can be readily machined, anodized, painted or powder

coated.

Examples of usage would be: cabinets for the electronics industry, hand and
power tools for industrial and home use, general hardware appliances, pump
parts, plumbing parts, parts for the automotive industry, sports and leisure,
home appliances, a lot of communications equipment, the list is endless.

Zinc die castings - poured from Zamak #3,#5 or #7 or a zinc-aluminum alloy

casting made from ZA-8, are made very similar to aluminum die casting.

The molten metal is injected into a closed vessel called a casting die or mold
under high pressure and at a controlled temperature.

The metal is cooled rapidly until the solidified part is sufficiently solid enough, to
permit it to be ejected from the mold.

The mold has sections which include the "cover" or hot side and the
"moveable" or ejector side. The die may also have additional moveable
segments called slides, or pulls which are use to create features such as
undercuts or holes which are parallel to the parting line.

Zinc die casting dies or molds operate in hot chamber die casting machines.
These machines run at the required temperatures and pressures to produce a
quality part, to net-shape or near net-shape specifications. Zinc die castings,
can be readily machined, plated, painted or powder coated.

Examples of usage would be: all general hardware type parts, hardware for
doors, drawers, and furniture, plumbing fixtures, automotive products, parts for
the lighting industry, all hand tools, power tools, sporting goods – list is endless.:
all general hardware type parts, hardware for doors, drawers, and furniture,
plumbing fixtures, automotive products, parts for the lighting industry, all hand
tools, power tools, sporting goods – list is endless.

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H.) POWDERED METAL CASTING – this process is also sometimes referred to as

the sintered metal process, we will always refer to this as Powdered Metal
Casting.

Casting Industry professionals across industry depend on Powdered Metal, for

cost effective production of parts.

The Powdered Metal Casting Process is the absolute choice for parts that
require high mechanical properties with repeatable close tolerances. That's
why this modern technology is so popular today.

The advantages of Powdered Metal Casting process are:

1. Unlimited choices of alloys and associated properties

2. The metal properties can be specialized for most any application

3. The process is suited well for moderate to high production quantities

4. Powdered metal process offers long term reliability, too. Close control of
dimensions and physical properties are an inherent part of the process. In
addition, powdered metal parts are produced with net shape, requiring little
secondary operations like machining.

The Powdered Metal Casting Flow Process Description:

1. 1. dispense measured quantity of powder metal into mold

2. 2. compact powder with high pressure machine tool
3. 3. extract compacted part
4. 4. sinter part in an inert atmosphere at controlled temperature and time

Examples of usage would be: fan hubs, motor hubs, magnets, automotive,
farm, aircraft service equipment, power tools, machine tools, etc.

I.) OTHER PRECISION MOLDING AND CASTING PROCESSES

Acurrad Process

Plaster Molding

Antioch Process

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Graphite Molding

Are some of the other processes

III. Special Casting Processes

A.) THE "V PROCESS " - permits molds to be made for the first time, out of
free-flowing, dry, un-bonded sand without using high pressure squeezing,
jolting, slinging, or blowing as a means of compaction of the sand used in
conventional casting.

This process is dimensionally consistent, economical, environmentally and

ecologically acceptable, energy thrifty, versatile and clean.

How it all works:

A thin plastic film is heated and place it over a pattern. A vacuum tightly draws
the film around the pattern which is then surrounded by a flask. Next, the flask
is filled with dry, un-bonded, extremely fine sand and vibrated, so that the sand
tightly packs the pattern. A second sheet of film is placed on the flask, a
vacuum draws out the remaining air, and the completed mold is then stripped
from the pattern.

Each half of the mold is made in a like fashion. Aluminum or the Alloy of
choice, is poured to form the casting.

Examples of usage would be: the medical equipment, instrumentation,

electronics, machine tool , aircraft machine tools, musical drivers ( speakers ),
church bells, automotive testing and repair equipment, to mention just a very
few applications.

Use the Table of Contents, to visit the Exploded Drawing Section and see a
colored drawing on the V-Process.

Follow the numbered steps listed below to get a better understanding of this
V-Process.

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1. set a pattern on a hollow carrier plate.

2. a heater softens up a thin sheet of plastic film.
3. film is draped over the pattern, and a vacuum sucks the film down over the
pattern.
4. flask is set on the film coated pattern.
5. flask is filled with dry sand, it is vibrated slightly to settle the sand.
6. the sprue-cup is formed, the mold is leveled…the sprue-cup and flask are
covered with plastic film.
7. vacuum is applied to flask, and hardens the sand, containing the pattern.
8. cope and drag are both formed in this manner and assembled.
9. plastic lined cavity is under vacuum.
10. molten metal is poured in, left to cool, part is done, plastic melts
evaporates away into sand.

B.) STYRA FOAM MOLDING – think of permanent molding, or sand casting,

green sand molding. But, instead of sand, a permanent molding tool,
STYRO-FOAM is used as the pattern material. Most times the styro-foam pattern
is laid out by a computer, then air cut to the shapes needed, or many shapes
fastened together to form pattern.

During the casting process, which would be just like sand casting, with the
pouring of molten metal into pattern cavity, which in this process is styro-foam,
sometimes the styro-foam is burned away, and sometimes it is not. This
depends on the application of the actual component being cast.

See Lost Foam Casting above, and visit the exploded drawings or views
Sections.

Examples of usage would be: large tooling for aircraft, bridge decking,
highway barrier components, elevator components, to mention a few
applications.

C. OTHER SPECIAL MOLDING AND CASTING PROCESSES –

Continuous Castings

Slush Castings

" No-Bake" Casting Process

Squeeze Casting

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There are many more Casting Processes, and variations, all of which have their
purpose in the casting of parts.

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