In addition to the wide range of casting processes available to produce nearly any engineered geometry, the versatility of the metalcasting process is also demonstrated in the wide range of alloys cast in various production rates in today’s metalcasting facilities. Without a doubt, any metal that can be melted is being cast into engineered components.
Metals can be categorized into two basic groups—ferrous and nonferrous. Ferrous metals are those in which iron is the prevailing constituent. In its simplest terms, ferrous alloys consist of cast irons and steels. Nonferrous alloys are those in which iron does not constitute a significant part of the metal structure. Typical nonferrous metals are aluminum, copper, brass, bronze, magnesium, nickel and titanium.
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Iron Alloys |
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Iron castings are produced by a variety of molding methods and are available with a wide range of properties. Cast Iron is a generic term that designates a family of metals. The six types of cast iron are gray iron, ductile iron, compacted graphite iron (CGI), malleable iron, white iron and alloyed iron.
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Steel Alloys |
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Steel castings have a variety of end-use applications that require a heavy-duty component. These castings are used in parts for railroad cars, pumps and valves, heavy trucks, construction and mining equipment and power generation equipment. A good steel casting application can provide strength while utilizing a flexible geometry inherent with the metalcasting process.
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Aluminum Alloys |
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Cast aluminum components are used for many functions, from decorative home-owner components, such as lighting fixtures, to highly engineered, safety-critical components for aerospace and automotive applications.
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Copper Alloys |
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Cast copper alloys are known for their versatility. They are used in a wide range of applications, such as plumbing fixtures, ship propellers, power plant water impellers and bushing and bearing sleeves, because they are easily cast, have a long history of successful use, are readily available from a multitude of sources, can achieve a range of physical and mechanical properties and are easily machined, brazed, soldered, polished or plated.
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Magnesium Alloys |
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Cast magnesium alloys have gained popularity in recent years due to their ability to maintain high strengths at light weights. Magnesium possesses unique properties that can open the door to important markets for structural applications and has gained widespread use in automotive components. Further, non-automotive applications, spurred on by the computer, electronics and power tool industries, continue to expand.
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Diecast Zinc Alloys |
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While traditionally focused in automotive, hardware and plumbing markets, diecast zinc alloys have become an alternative material of choice in consumer product industries such as communications, electronics and home appliances.
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