Quality Casting Manual

Quality Casting Manual

Qingdao Casting Quality Industrial Co., Ltd.

Founded in 2002, Qingdao Casting Quality Industrial Co., Ltd has grown from small company to a professional supplier of casting parts. We pay much attention to the quality and inspection , Our products are much more casting and forging parts.The method inclu sand casting ,lost wax casting and die casting .Today, its products are marketed globally through many countries.

Much buyers from all over the world purchase products from China. But do you know the quality of products in China? Maybe you only pay the surface and price , but the inner qu is lost . Why You Choose Casting Quality As Your Partner? Honesty

We will honestly inform you whether we can produce your products, and inform you the process of products . Yes , you have the right to get the actual details include manufacture process, quality, shipment and the problems. The honesty will be benefit to your firm and us .

Innovation

Our engineers are more than just designers....they are pioneers. Our team use CAD/CAM do the simulation of casting parts .Through the advanced technology , we can know the weight and structure . We also visited so many factories to know their difference and imp our products every year.

Quality

We are obsessed with quality. Casting Quality constantly strives to exceed our customers expectations in durability and performance. In fact, we will control the whole process fro original material to the finished parts ,include the technology .Uniquely-designed Quality Control System focuses on ensuring four product goals: 1) Eligible Chemistry , 2) Hardne 3) Mechanical Property and 4) Affordable Pricing. The result is the best casting products value in the industry. P

Service

r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

We are located in Qingdao, China, It has convenient transportation of road and sea. Courteous service is part of who we are, and we do it better than anyone in the industry. Casting Quality you can expect friendly, knowledgeable and prompt customer service. Shipping orders complete and on-time is of paramount importance to our costumers. We count the delivery date and result before accept your order .Casting Quality consistently ranks as one of the best in speed of delivery and fill rates.

Web Site: www.castingquality.com Email: [email protected]

Qingdao Casting Quality Industrial Co., Ltd.

What is casting?

Casting is a mass production process which involves molten materials (such as metals, plastics or resins) being poured into a mold, allowed to solidify and then extracted for use. Casting can be thought of as a method for reproducing somet - whether a mere part or a single unit by itself. Casting is a process that can be used to manufacture complex parts which would prove too expensive or time-consuming to produce using other methods such as cutting or shaping these from solid materials.

Casting Processes Classification

1. Type of Mould - Consumable (sand): destroyed after each casting - Permanent (metal): reused many times 2. Type of Pattern (for making a sand mould): - Consumable (wax): destroyed (melted) for each mould - Permanent (wood, metal): reused for many moulds 3. Type of Core (for producing a hole in a casting): - Consumable (sand): used in both sand and metal mould - Permanent (metal): used in permanent mould only 4. Type of Filling (metal flow in mould): - Gravity: sand casting, gravity die casting - Pressure: low and high pressure die casting - Vacuum: vacuum investment casting. P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

We can supply products by sand casting and lost wax castin

Web Site: www.castingquality.com Email: [email protected]

Qingdao Casting Quality Industrial Co., Ltd.

What Is Sand Casting? Sand casting is used to make large parts (typically Iron and Steel but also Bronze, Brass, Aluminum). Molten metal is poured into a mold cavity formed out of sand (natural or synthetic). The processes of sand casting are discussed in this section, include patterns, sprues and runners, design considerations, and casting allowance. Patterns

The cavity in the sand is formed by using a pattern (an approximate duplicate of the real part), which are typically made out of wood, sometimes metal. The cavity is contained in an aggregate housed in a box called the flask. Core is a sand shape inserted into the mold to produce the internal features of the part such as holes or internal passages. Cores are placed in the cavity to form holes of the desired shapes. Core print is the region added to the pattern, core, or mold that is used to locate and support the core within the mold. A riser is an extra void created in the mold to contain excessive molten material. The purpose of this is feed the molten metal to the mold cavity as the molten metal solidifies and shrinks, and thereby prevents voids in the main casting.

In a two-part mold, which is typical of sand castings, the upper half, including the top half o the pattern, flask, and core is called cope and the lower half is called drag. The parting line the parting surface is line or surface that separates the cope and drag. The drag is first fille partially with sand, and the core print, the cores, and the gating system are placed near the parting line. The cope is then assembled to the drag, and the sand is poured on the cope hal covering the pattern, core and the gating system. The sand is compacted by vibration and P mechanical means. Next, the cope is removed from the drag, and the pattern is carefully r o f is removed. The object is to remove the pattern without breaking the mold cavity. This e s s facilitated by designing a draft, a slight angular offset from the vertical to the vertical surfa io n of the pattern. This is usually a minimum of 1?or 1.5 mm (0.060 in), whichever is greater. Th a l S rougher the surface of the pattern, the more the draft to b u p provided. p Sprues and Runners

li e r o f C a s t in g P a r t s In C h in a

The molten material is poured in the pouring cup, which is part of the gating system that supplies the molten material to the mold cavity. The Web Site: www.castingquality.com Email: [email protected]

Qingdao Casting Quality Industrial Co., Ltd.

What Is Sand Casting? vertical part of the gating system connected to the pouring cup is the sprue, and the horizontal portion is called the runners and finally to the multiple points where it is introduced to the mold cavity called the gates. Additionally there are extensions to the gating system called vents that provide the path for the built up gases and the displaced air to vent to the atmosphere. The cavity is usually made oversize to allow for the metal contraction as it cools down to room temperature. This is achieved by making the pattern oversize. To account for shrinking, the pattern must be made oversize by these factors, on the average. These are linear factors and apply in each direction. These shrinkage allowance are only approximate, because the exact allowance is determined the shape and size of the casting. In addition, different parts of the casting might require a different shrinkage allowance. Sand castings generally have a rough surface sometimes with surface impurities, and surface variations. A machining (finish) Sand casting is divided into many types : green sand casting, resin sand casting and Sodium silicate bonded sand casting. Green sand casting is a low cost method to get a product, which surface finish is not good. Resin sand casting will get a good surface and dimension, so it is widely used in automobile industry. Generally, there are two equipment which used to melt metal, one is cupola, the other is electrical stove. It is more easy to control temperature of iron water in electrical stove , so it will get a good quality in chemistry and mechanical property. But the cupola has a large capacity , it is widely used to cast the big body of machinery in gray iron material. The best method is combine the cupola and electrical stove , the cupola get a big capacity, the electrical stove keep a suitable temperature to improve the metal. Of cause, it only be used electrical stove to get the steel and higher ductile iron. If the products is very heavy or large size, if the tolerance is not strictly in dimension, We suggest to use sand casting in production. Sand casting is suitable to cast those material: ●

Gray Iron; Ductile Iron

●

Malleable Iron

●

Carbon Steel; Alloy Steel; Stainless Steel

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P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

Qingdao Casting Quality Industrial Co., Ltd.

What Is Sand Casting?

●

Copper, Zinc and Aluminum etc.

We are using the following processes to do sand casting, which you would like to choose with: The weight can be from 100grams to 10tons.

sand casting process

production way

order

quality price

weight(referance)

quantity

green sand casting better for making mould by hands smaller pass iron and light alloy aluminum making mould by lift-machine more normal copper alloy making mould by simple-machine middle superior making mould by production-line larger baking Resin sand casting better for no baking iron, normal for steel

Sodium silicate bonded sand casting better for steel no baking baking dry mould casting better for iron and light alloy

under 20kg under 30kg under 100kg

smaller and superior middle

over 5kg

smaller and superior middle

over 10kg

no baking by production-line larger baking

excellence

no requirement

superior

over 30kg

smaller and normal middle

over 5kg

smaller and pass middle

over 10kg

smaller and pass middle

over 50kg

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

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Qingdao Casting Quality Industrial Co., Ltd.

What Is Lost Wax Casting?

Lost Wax Casting( Investment casting; investment casting) is an advanced metal forming process use produce metal parts of the highest quality, functionality and cost-effectiveness. Lost Wax Casting is a one process in which one disposable pattern produces one metal part. When combined with modern production knowledge and technologies, Lost Wax Casting can be applied to produce parts of varying degrees of complexity, in virtually any volume and for the broadest possible spectrum of applications.

A highly versatile casting process, Lost Wax Casting has for some time been perceived as a comparat expensive process. But when compared to alternative processes which require extensive welding or machining, an investment cast component can often dramatically reduce overall part production cost

Lost Wax Casting which is also known as the "investment casting " process, traces its roots to the San Dynasty in China from 1766 B.C. to 1122 B.C. The method was brought into modern industrial use wh American manufacturers applied Lost Wax Casting( Investment casting) to make high quality military during World War II. It was found practical for many wartime needs - and during the postwar period i expanded into many non-aircraft applications. Today, Lost Wax Casting( Investment casting) is recogn and used worldwide as a technique for producing close-tolerance metal parts at highly competitive co

When performed by experienced and knowledgeable casting specialists, Lost Wax Casting( Investmen casting): Allows greater design freedom for very simple to highly complex parts Provides superior repeatability Can utilize a wide variety of alloys Yields lighter, stronger metal parts with superior finishes Reduces labor, tooling and machining costs Allows very rapid prototype development

P r o f e s Of course, Lost Wax Casting( Investment casting) is not the appropriate process for every metal part s io n casting requirement. However, for many challenging part applications, Lost Wax Casting( Investment a l a proven and cost-effective metal forming solution. S u p p li e r o f C a s t in g P a r t s In C h in a

AS professional supplier of casting

part, the quality and prompt delivery is very important. WE have owned logistics system to guarantee it. Web Site: www.castingquality.com Email: [email protected]

Qingdao Casting Quality Industrial Co., Ltd.

What Is Lost Wax Casting?

How to control the lost wax casting : Casting size and shape determines the tolerance required t for process variables. Many process factors affect investment casting tolerances, such as: 1. wax temperature 2. wax die temperature 3. the amount of pressure applied to inject into a die 4. firing temperature of the ceramic shell 5. ceramic mold refractory composition 6. cooling rate of the metal 7. lot to lot variation of raw materials

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Qingdao Casting Quality Industrial Co., Ltd.

What Is Lost Wax Casting? There are three type lost wax casting in China. One is Sodium Silicate process investment casting, one is Colloidal Silica Technology investment casting, another is combined process casting (combined Colloidal Silica and sodium silicate process). The sodium silicate investment casting is low cost investment casting, it mainly cast carbon steel. The colloidal silica investment casting is high cost investment casting ,but it can be resisted to high temperature to cast stainless steel ,and it can get a very strictly tolerance and good surface finish with very small weight. The combined technology is the intergraded in the other two type investment casting. It can also do carbon steel and stainless steel. We can use those three type lost wax casting to do carbon steel, alloy steel and stainless steel. We also can cast ductile iron as purchaser’s specification. The products is following: ●

1. Valve parts : valve body , disc, bonnet and others .

●

2. Pipe fittings : Stainless steel threaded fittings , ductile iron fittings and malliable iron fittings .

●

3. Automobile parts

●

4. Pump parts

●

5. Machinery accessories

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Qingdao Casting Quality Industrial Co., Ltd.

Automobile Parts

Products List

Our line of products include the parts for the automobile industry. We manufacture different types of cast or forge parts for various applications in the automobile industry ranging from the engine to the brakes and the all possible accessories as per customers¡¯ requirements, our parts with positive quality has win the high reputation from the customers of automobile manufacturer, parts manufactured under ISO or QS process. When you send us a inquiry , Pls indicate the following items : ∉

Weight ( roughness part or finished part)

∉

Material ( Detailed Steel or Iron Grade)

∉

T olerance

Q uant it y The drawing can be made by software of Auto CAD , Pro/Engineer or Solid works

∉

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

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Qingdao Casting Quality Industrial Co., Ltd.

Pump Parts

Products List

The casting part are popular used in pump industry, such as Pump accessories Pump Shell 06 Pump Part 04 Multistage Pump Part. The material are grey iron, ductile iron, carbon steel, alloy steel and stainless steel. Especially, the lost wax casting can get a good quality in pump field.

When you send us a inquiry , Pls indicate the following items : ∉

Weight ( roughness part or finished part)

∉

Material ( Detailed Steel or Iron Grade)

∉

T olerance

Q uant it y The drawing can be made by software of Auto CAD , Pro/Engineer or Solid works

∉

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

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Qingdao Casting Quality Industrial Co., Ltd.

Valve Parts and Pipe Fittings

Products List

The valve casting is different with others , our foundry have more the 10 years experience in this field, We can use sand casting to do grey iron and ductile iron, and use lost wax casting to do carbon steel and stainless steel. The casting part can reach 10tons in ductile iron valve body.

When you send us a inquiry , Pls indicate the following items : ∉

Weight ( roughness part or finished part)

∉

Material ( Detailed Steel or Iron Grade)

∉

T olerance

Q uant it y The drawing can be made by software of Auto CAD , Pro/Engineer or Solid works

∉

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

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Qingdao Casting Quality Industrial Co., Ltd.

Machinery accessories

Products List

The products include machinery body, base and other accessories. We can use sand casting and investment casting to do all parts.

When you send us a inquiry , Pls indicate the following items : ∉

Weight ( roughness part or finished part)

∉

Material ( Detailed Steel or Iron Grade)

∉

T olerance

Q uant it y The drawing can be made by software of Auto CAD , Pro/Engineer or Solid works

∉

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

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Qingdao Casting Quality Industrial Co., Ltd.

Fastener: Bolt & Nut

Products List

The fastener factory is mainly supply high strength bolt , The Standard can be applied to : ∉

Bolt: DIN 6914/ DIN 6915/ DIN 6916

∉

Nut: DIN 931/ DIN 601/ DIN 7790/ DIN934/ DIN 555

∉

BS1083/ BS 1768/ BS 1769

∉

ASTM A193-B7/ ASTM A194-2H

∉

ISO 4014

When you send us a inquiry , Pls indicate the following items : ∉ ∉

Thread Type (DIN, ISO or NC) Material ( Carbon Steel or Alloy Steel)

∉

Length

∉

Washers

∉

Q uant it y

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Qingdao Casting Quality Industrial Co., Ltd.

Butterfly Valve and Gate Valve

Products List

Tieling Valve (Group) Machinery Co., Ltd. is the biggest valve maker in China. It mainly supply

low pressure valves, especially in large size valves. As export office, pls send us the English inquiry to us. The material is ductile iron and grey iron in valve body and disc. The size can reach 2.8m. We also have perfectly machining capacity and testing machinery.

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

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Qingdao Casting Quality Industrial Co., Ltd.

International Standard C a s t i n g To l e r a n c e

I S O

8 0 6 2 : C a s t in g s S y s t e m

Required Machining Allow ances (RMA)

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o f d im e n s io n a l t o le r a n c e s

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

Qingdao Casting Quality Industrial Co., Ltd.

International Standard To l e r a n c e g r a d e s f o r l o n g - s e r i e s p r o d u c t i o n r a w c a s t i n g s

To l e r a n c e g r a d e s f o r s h o r t - s e r i e s o r s i n g l e - p r o d u c t i o n r a w

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I S O

8 0 6 2 : C a s t in g s S y s t e m o f d im castings e n s io n a l t o le r a n c e s

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

Qingdao Casting Quality Industrial Co., Ltd.

International Standard

I S O

8 RMA grades recommended for particular metals and alloys and manufacturing methods0are 6 presented in table B.I. 2 : C a s t in g s S y s t e m o f d im e n s io n a l t o le r a n c e s Web Site: www.castingquality.com Email: [email protected]

P r o f e s s io n a l S u p p li e r o f C a s t in g P a r t s In C h in a

Qingdao Casting Quality Industrial Co., Ltd.

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Qingdao Casting Quality Industrial Co., Ltd.

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