Foundry Process

Manufacturing

Foundry

Depending on the material, we use a wide range of foundry processes to achieve high-end results, including:

Permanent Mold Casting (Permold)/ Gravity Die Casting

Permanent mold casting is a type of foundry process used to manufacture castings in bulk, by using permanent metallic reusable molds. The result is dimensional stability and superior surface finish. The process produces a strong casting with smooth surfaces, and little or no defects.

The mold, also known as a die, is created using highly durable materials that can withstand many thermal cycles. More importantly, it is a custom process that saves time and money, inevitably becoming the preferred choice of several customers.

The Process

Depending upon the metal casting business, the permanent mold chill casting process is broken into four key steps — creating the mold, pouring molten metal into the mold, cooling the metal, and opening the cast.

The first step is to create a mould, and it requires much attention to detail. In this step, no sand is used, and the entire mould is created as one solid part.

1

The machined moulds and required cores are then assembled into a die assembly.

2

The metal is poured into a die and flows under the force of gravity, while being skillfully tilted to properly fill the mould.

3

After the casting is removed from the cavity, the moulds and cores are cooled in a proprietary solution, readying it for the next cycle.

4

The permanent mold manufacturing process requires special design capabilities. Rapsri has an in-house R&D team equipped with manufacturing capabilities for high-end permanent mold design based on solidification simulation.

The Advantages

Low, medium, and high volume production

Fine grained, uniform, and reproducible microstructure

Tighter grain boundary resulting in higher conductivity – minimum 99% IACS

Superior surface finish

High-end mechanical properties

Low, medium, and high volume production

Fine grained, uniform, and reproducible microstructure

Tighter grain boundary resulting in higher conductivity – minimum 99% IACS

Superior surface finish

High-end mechanical properties

Continuous Casting

Continuous casting is a process where metals and alloys can be simultaneously shaped and solidified through a seamless process. Keeping energy efficiency, cost effectiveness, and productivity in mind, we use world-class machines for our continuous casting process.

Given the high demand, tubes and solids are the most commonly manufactured continuous casting shapes. However, shapes such as squares, rectangles, and hexagons can also be produced based on customer requirements.

The Process

Molten metal from an induction furnace is fed into a mould with the required shape.

1

The molten metal enters the die through a series of holes in the upper portion of the mould.

2

A water-cooled jacket surrounding the extracts the heat to solidify the metal.

3

Once the solidification occurs in the die, the solidified metal casting is then pulled through the bottom of the die by a mechanical puller at controlled increments and speed.

4

The lengths are finally cut off by a travelling saw that moves with the cast shape.

5 The Advantages

Ability to cast regular shapes and certain irregular configurations in long tubular form, which is difficult for other casting methods

Fine grained, uniform, and reproducible microstructure

Continuous cast material is consistently dense and homogeneous in structure, and therefore, well-suited for pressure applications

Various profiles like squares, rectangles, triangles, polygons, and any other symmetrical shaped profiles can be cast

Straight, true, and concentric product for high-speed bar machines

Ability to cast regular shapes and certain irregular configurations in long tubular form, which is difficult for other casting methods

Fine grained, uniform, and reproducible microstructure

Continuous cast material is consistently dense and homogeneous in structure, and therefore, well-suited for pressure applications

Various profiles like squares, rectangles, triangles, polygons, and any other symmetrical shaped profiles can be cast

Straight, true, and concentric product for high-speed bar machines

Sand Casting

Sand casting is the most versatile among manufacturing methods, and opens up a range of possibilities. One of the advantages of using this method is that several metals and alloys can be chosen to form the cast parts. In this process, molten metal is transferred into an expandable sand.

We collaborate closely with reliable foundry partners to provide sand casting solutions.

The Process

Our shell molding process coupled with RAPOUR pouring technology gives the best combination of physical and mechanical properties with very high casting integrity. RAPOUR technology ensures a fine grain structure and microstructure comparable to the chill cast process. Good surface finish and close dimensional tolerance reduce the need for machining and preserve the aesthetics of a cast finish.

Besides, we also collaborate closely with reliable foundry partners to provide advanced sand casting solutions.

In the pattern making step, a replica of the object to be made is cast using a suitable material.

1

In the mould making step, the mould makes a cavity in the sand which exactly matches the form to be produced. The sand is usually bonded to a metal part, called a cope and drag.

2

In the clamping step, the cope and drag halves fit together to form a tight seal.

3

In the pouring step, molten metal, maintained at a certain temperature, is poured into the seal. It passes through the mould, resulting in the finished product.

4

In the cooling step, the metal inside the cavity is cooled and solidified.

5

Post the cooling period, the solidified mould breaks out of the casting.

6

In the seventh and final step of trimming, the finished product is cleaned, and all extra projections are removed.

7 The Advantages

Complex shapes and intricate details can be cast easily

Large selection of alloy grades to choose from

Mass production with automated production process

Thin section can be cast

Fine grain microstructure

Complex shapes and intricate details can be cast easily

Large selection of alloy grades to choose from

Mass production with automated production process

Thin section can be cast

Fine grain microstructure