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Posted on Sep 2, 20201
The casting process involves transforming molten metal into a pre-designed form or shape and is the most preferred method of the metal forming process, simply because it has many inherent advantages that enable it to create complex and integral streamlined parts that cannot be obtained by other comparable methods.
In addition, the development of science and technology has made it possible to cast parts that are practically impossible to make by any other method, such as forging, welding or stamping. Some of the most important advantages of using castings as a manufacturing process are listed below.
The greatest benefit that prompts manufacturers to use castings is the enormous design flexibility. Any object weighing from 5gm to 200 tons of any shape or size is easy to throw. It is very flexiblea methodology that allows for complex design techniques that cannot be applied to other production methods. In addition, it enables a quick transition to the finished product as it involves a very simple and uncomplicated production process. Molten metal is poured into a cavity with dimensions similar to that of the final product. Casting is undoubtedly the simplest and most popular method of forming metal. Moreover, the physical properties of some metals only require a casting process as it is not possible to remodel them into bars, rods or plates. Casting offers the best design flexibility compared to other production methods such as forging, welding, rolling or stamping.
Casting also has the considerable advantage of being able to create attractive patterns as there is no restriction on the assembly of elements or shapes. There are several types of casting processes that can be used to achieve the desired finish of the casting. Sand molding provides a rugged appearance, and other methods such as shell molding and lost wax casting provide a smoother surface. Casting also helps to minimize the residual stresses in the finished product that come from the casting.
Casting is arguably the most reliable and durable method of metal casting as it uses good design principles and performs periodic mechanical property testing to test molten metal cast rods. This ensures high reliability and the reusability of the metal, which is usually not possible with other methods. In addition, the highly reliable method enables designers to combine several parts into one production, reducing the possibility of future leakage. This also makes casting a reliable method of forming metal.
The cost saving is perhaps the most important benefit of using a casting process. Since casting allows multiple parts to be combined into one production, it drastically reduces production costs. It also requires shorter production lead times, which also translates into lower costs. In addition, flexibility and design freedom contribute to minimizing the costs associated with machining and excess metal.
Most cast iron manufacturers combine casting with another process that appears to be more efficient or better suited to the requirements of a particular project.
There are many suppliers of iron castings in China, and most of them export iron and steel castings overseas each year. In the past, these foundries had a good time to develop. However, in recent years their situation has become very difficult.
1. The unstable prices of pig iron.
Pig iron prices are the basis for cast iron and have a direct impact on the cost of cast iron, and therefore on the prices of iron castings. The price of pig iron has increased in recent years. What's more, the price of pig iron is still rising day by day. Some iron foundries are currently difficult to control production costs.
2. Unstable exchange rate of USD to RMB.
Due to the continuous appreciation of the RMB, the USD / RMB exchange rate fell from 6.81 to 6.60 in 2010. A 3% devaluation resulted in the closure of some iron foundries. Nowadays, the rate continues to decline. It is difficult to estimate the level of the exchange rate in 2011, but one thing is certain that in the new year the exchange rate will continue to decline, which will be another bad factor for exporting companies.
3. Increased workers' salaries.
Due to the continued appreciation of RMB and the rise in raw material prices in China, workers' wages increased significantly, according to our estimates in the foundry fields, wages increased by about 30% to 35%, which will increase the production costs of metal foundries.
Therefore, the current situation of China's iron casting suppliers is very difficult at the moment, and perhaps even more difficult in 2011. We hope that stable pig iron prices and the exchange rate will allow metal foundries to survive. After all, metal casting is the backbone of the industry, if most of the metal foundries are closed, all manufacturers and suppliers in China and abroad will suffer terrible losses.
MTS gathered worldwide iron casting manufacturers into this online platform. Browse and search for your next supplier with us.
Should you run into any difficulties, please do not hesitate to contact us.