How are Automobile Casting Parts Made in a Steel Casting Factory

How are Automobile Casting Parts Made in a Steel Casting Factory

Casting is the process in which a liquored metal is melted into a mold of a specific shape. It is the preferred method in industries as it is cost-effective and produces precision parts. It can be carried out with almost all metals but the most widely used are aluminum, copper, and steel-based alloys. In this article, the automobile casting parts made in steel casting foundry are discussed.

Metal casting has many applications for casting ferric and non-ferric metals.  Many processes produce automobile parts that are economical, light-weighted, and of good quality. Major automobile parts produced by casting processes are valve covers, transmission housing, pistons, fan clutches, and wheels, etc.

 To cope with the need to make automobile parts light weighted and long last, Titanium and Magnesium alloy are used widely due to their good corrosive resistant performance. Aluminum silicon alloys are famous for the creation of casted internal combustion engines due to their good thermal conductivity power and less density which provides lightweight components.

The automobile industry provides a number of applications to casting processes which are constantly being advanced to cope with the industry standards. Different casting methods are used to produce a variety of complicated shaped auto castings. Some auto parts that need pressure, vibration, wear-resistance, and affordable rate e.g., pistons, cylinder blocks, piston rings, cylinder liners, etc. 

Some auto parts having complicated shapes e.g., cylinder heads, gearbox housings, and exhaust and intake manifolds can only be produced by casting. The previously used forging method has been replaced with casting due to advancements in casting technologies.

One of the largest casting steel foundry is dawang casting automobile industry and the. A number of automobile parts can only be produced using the casting process due to advancements in casting technologies. These parts are also discussed in this article.

Main auto casting features include complicated shapes, good reliability, lightweight, and huge production volume. Investment casting produces aesthetical products and has the ability to create complicated shapes with good tolerance. Its high corrosive resistance feature makes it the best choice for the auto industry. Following are some of the auto parts manufactured by casting processes:

1. Automobile Gray Iron Casting:

A cylinder block in automobiles is a gray iron casting. It is needed to be thin-walled and bears good strength. It has two types of implementations:

The low-carbon process is used to reduce the cast-iron strength by lowering the carbon and silicon content of cast iron. Its main benefit is that it can be comprehended by ingredients changing after the furnace. It has high reliability and costs less. The operational and pretreatment requirements are loose. 

The main drawback of this method is the poor performance of casting and low carbon equivalency. It is easily shrinkable and increases the stress of casting. The casting processing properties and the uniformity of the section are not so good. Also, thermal conductivity is affected.

2. Ductile Iron Auto Castings

These automobile castings are used in shell crankshafts, rear axle shells, camshafts, and various brackets.

3. Vermicular Iron Castings

These castings are widely used in automobiles parts such as horsepower engines and automobile exhaust pipes. High power cylindrical heads are prepared using graphite cast iron.

4. Austempered Ductile Iron (ADI)

This iron has comparable properties like good strength, toughness, and ductility. It can be divided into two categories: 900-1200 N/mm2 and 1200-1600 N/mm2. It is being rapidly developed in America and Europe due to its excellent properties.

5. Special Cast Iron

Advancements in engine performance, some casting heat requirements like exhaust pipes are increasing. Hence, medium silicon molybdenum iron, silicon molybdenum ductile iron, and high nickel ductile iron appeared.

6. Zinc Aluminum Alloy

This tool has very good flexibility, malleability, and strength which do not match with any other material. Zinc and aluminum have a low melting point and consume less production energy.

Conclusion

In this article, the automobile casting parts made in steel casting foundry have been discussed. Metal casting finds a wide range of applications in the automobile industry and there are many largest casting industries present.  

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By Fahim Hasan

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