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Have you ever imagined or questioned how manufacturers create different shapes using steel or any other metal? Mainly, the manufacturers use several methods like machining the body out of solid metal or steel casting to develop various structures using metal. But, the most commonly used process is steel casting, which is done at the steel casting foundry.

The steel casting foundry uses two main methods to cast steels, i.e., using reusable and expandable molds. In this article, we will discuss some of the best steel casting processes using reusable and expandable molds.

Casting Method Used in Steel Casting Foundry

Permanent mold casting is one of the best methods used at an industrial level to cast steel. The method involves a permanent mold made up of any metal with a higher boiling point than steel. The melted fluid is poured without additional pressure to distribute the liquid uniformly to cast the steel. After the steel solidifies, the permanent mold is removed for reuse. Hence, permanent mold casting is considered a reusable casting method.

Semi-permanent mold casting has a similar casting process as permanent mold casting, but the only difference is the cores used in the casting process. The semi-permanent mold casting can include the expandable sand cores besides the metal cores. Hence, different and complex core shapes are easily achieved using the method of casting. Small holes are kept to remove the excessive metal fluid inside by shaking on a vibrating table.

Pressure casting is a very controlled method of steel casting that uses outside force in place of gravity to control metal flow. The pressure casting uses gas, vacuum, mechanical or centrifugal forces to complete the casting process. With this method, the steel casting foundry forces are easily controllable. Pressure casting is an excellent method to get a shiny surface finish, as the fluid is distributed uniformly inside the mold.

Sand casting is one of the ancient and most used expendable casting methods used to cast steel. Sand casting is the cheapest method that is readily available to create structures out of metals. Also, the sand absorbs higher temperatures quickly and can make any shape. The cores steel casting foundry created using this method are easier to remove than any other methods in the list. But, with sand casting, producing large and rugged pieces is more preferred.

Shell molding is similar to sand casting as it involves sand with a slight modification. In this process, the sand is mixed with resin to make it strong and retain its shape. The mixture of sand and resin forms a shell, and hence called shell molding. Shell molding is an exact steel casting technique used in steel casting foundry that gives a smooth appearance to the structures.

Creating different shapes using metals might look complicated, but the melted form of these metals can be given an outline using the above techniques easily. Most steel casting foundry uses the above methods to make different objects using steel.