All About Steel Casting That You Want to Know

Steel Casting

As the term suggests, steel casting is the process of casting different types of steel. It is usually used where cast iron falls short, either because of its strength or its shock resistance. There are many applications of steel casting, such as forging presses, gears, pump casings, marine equipment, hydroelectric turbines, turbocharger turbines, valve bodies and engine cylinders.

If you need steel parts, you will find a number of reputable steel castings exporters India. Most such casting manufacturers work with other metals with specialisation in steel parts. Steel is cast to create parts with extreme precision and used across many industries. Casting allows us to create highly complex and intricate products to make them functional.

Steel Casting

In the casting method, we give a desired shape to a metal (here steel) by pouring it into a mould cavity. The molten metal slowly cools, solidifying and hardening in the process. The mould is then broken or removed to bring out the enclosed metal, which is now shaped into the desired part. This was one of the preferred way of using iron. It was used to make weapons and tools. Even today we use cast iron for many applications.

Steel is an alloy of iron, carbon and some other elements. Steel has replaced many of the applications where iron was used, making steel one of the most common object to be used in casting. The two metals may seem similar, but each has its own unique characteristics. Let us see a comparison between the two metals:

Strength:

Both still and iron show the same kind of strength. However, cast iron has higher compressive strength.

Cost:

Steel is more expensive than iron, which makes its casting cheaper. This is because steel is more difficult to cast. Steel has a higher melting point and a tendency to shrink.

Corrosion resistance:

This is one of the biggest reasons steel is preferred over iron is because of its ability to better withstand corrosion. Iron rusts easily when exposed to moisture. Steel is also susceptible to corrosion. However, it is formed to resist corrosion for longer. This makes steel longer lasting metal. This is why even though steel casting may be a tad more expensive, it is actually economical in the long run.

Design considerations

In investment casting, our prime requirement is quality components. We are looking for components that are durable and provide superior performance. We need strict process controls, a sound mechanical design and a thorough understanding of the market. It is also important to have a good understanding with the design and engineering teams in steel castings exporters India. There are some important design considerations that you have to keep in mind:

Size and weight:

One of the major factors when deciding mould dimensions are part size and weight. These two factors decide the mould capacity as well. One also has to consider that when multiple pieces are run on a single casting, costs are lowered. The key here is to fully utilize the production line by casting small pieces together.

Design:

As explained above, steel is harder than iron to cast. It can be a trickier to work in complex designs or designs with intricate contours. Since it does not melt easily, it does not take the mould’s shape easily. So, a manufacture will always consider the complexity of the design. A complex part could be broken into smaller parts.

Gates:

The most efficient form of casting is when we use a single gate. It gives us a higher yield per mould and reduces the weight to be pored in each mould. It also ensures dimensional stability.

Process controls:

Manufacturing standards have to be kept under strict process controls. This is important to ensure the overall stability of the part. The compliance with quality controls is also necessary for keeping up with recognized certifications such as ISO and GMO standards. The quality control of individual parts decides the overall quality of the entire product.

Quality of the metal:

Steel is an alloy. It can have impurities that can improve or hamper the casting process. The quality of the steel is a major consideration for steel castings exporters India. High grade steel may increase costs, but it needs less rework and wastage.

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