How do you design castings first-time right?

One of the most pressing issues in the world of cast pieces is a correct design of both products and casting systems, so as to achieve a flawless casting. How do you approach this and what parameters should you take into account? You will find out in one of the modules of the foundry technology course being organised by Sirris from 12 April.

A good casting starts with a thorough check of the melt bath. Knowing the most significant parameters of the metal melting process is essential in this respect. What should you look out for in the melt bath in order to obtain the right quality of the cast product? What are the most significant melting losses? What happens in the melt bath depending on time? How much energy do you require? These are but a few of the questions that are answered during the course.

Temperature, oxygen content and chemical compositions measurements are needed for determining the characteristics of the melt bath. The measurement methods for ascertaining these properties are explained. You can easily deduce a number of characteristics from the thermal analysis that provide insight into the process, allowing you to correctly establish the requirements of castings together with your supplier.

The mould cavity must be filled for each casting during casting, whereby a number of basic rules must be respected so as to obtain flawless pieces.  These rules will be explained extensively, thus enabling you yourself to calculate a correct dimensioning of the casting system.

Metals are also inclined to shrink when solidifying. A few rules of thumb allow this shrinkage issue to be tackled and resolved, so that castings contain no shrinkage cavities. Simulation techniques make it possible to calculate the increasingly more complex geometries, so as to achieve castings of optimal quality.

Proper dialogue between customer and manufacturer of the casting is indispensable: Although the foundry can indeed correct the shrinkage behaviour with a number of techniques, it is at least just as important that the basic design of the casting meets the requirements of the casting process. The course thus delves deeper into the do's-and-don'ts of a good casting design.

Casting errors may still arise due to the casting process itself, or as a result of a non-optimal design. This is why the course equips you with a catalogue of casting errors and their causes, meaning you can provide corrective measures together with your castings supplier.

If you are interested in our first-time right casting designs, you will find all the information on the foundry technology course starting near you soon in our agenda.