Intelligence – Insight – Ingenuity

I want advice on what processes are best suited to my component

Getting it right

At MRT Castings we want to ensure that we provide you with the right solution, tailored to your requirements. Not only do we have a range of casting processes available but we can provide you with advice and guidance based on years of industry experience. Take a look at our Castings Chart below and we can then discuss your requirements further.

Which is the right casting process for me?

High Pressure
Die Casting  


High Pressure Die Casting provides the shortest route from molten metal to completed component. Molten aluminium or zinc alloy is injected into a hardened tool steel mould and allowed to solidify under pressure before ejection.

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Tooling

Hardened tool steel moulds. Relatively expensive tooling, but pays back in lower unit costs.

Volumes

The most economic method for high volume production, typically demand of 2,000 to­ 500,000 per annum.

Wall Thickness

Min. Wall Thickness 1-2mm.

Surface Finish

Excellent Surface Finish. No trimming required apart from to remove in-gates.
 

Accuracy

Highest dimensional accuracy.

 


Gravity
Die Casting   


Gravity Die Casting employs cast iron moulds which allow aluminium and zinc castings to be produced more accurately and cheaply than with sand casting. Rapid chilling gives excellent mechanical properties whilst non-turbulent filling ensures production of heat treatable gravity castings with minimal porosity.

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Tooling

Cast Iron or Steel Moulds. Moderate tool and unit costs.
 

Volumes

Suits demand of 250 to ­50,000 per annum.
 

Wall Thickness

Min. Wall Thickness 3-4mm.

Surface Finish

Good Surface Finish, but with slight texture due to die coatings.
 

Accuracy

Moderate dimensional accuracy

 


Sand
Casting  


Sand casting offers the simplest medium for production of non ferrous castings, by pouring molten zinc, aluminium or copper alloys into a sand mould.

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Tooling

Wooden or Resin Patterns. Lowest Tooling cost, but higher unit production costs.

Volumes

Ideal for prototypes and small volume production, of 1 to 500 per annum.
 

Wall Thickness

Min. Wall Thickness 3-5mm.

Surface Finish

Fair Surface Finish. Parts will generally be shotblast to improve appearance after removal from the mould.

Accuracy

Least accurate process

 


I WANT TO RECEIVE ... ADVICE ON WHAT PROCESSES ARE BEST SUITED TO MY COMPONENT

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