By Shannon Wetzel, Metal Casting Design and Purchasing 

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Metal castings often are problem-solvers for their customers, providing ways to reduce cost, reduce weight and improve performance of their end-products. But are there some problems you haven’t been able to solve because conventional metals did not provide the suitable properties?

Gray and ductile iron will meet the needs of most of your iron casting applications, but a small, yet growing percentage of applications require material with higher strength, higher thermal properties and higher wear resistance. Austempered ductile iron (ADI), compacted graphite iron (CGI) and high silicon molybdenum  (SiMo) ductile iron carry with them unique properties that go beyond that of the conventional irons and can be competitive with other materials such as aluminum and steel. If you haven’t already, considering them for your next component can expand your potential for reducing weight and cost while achieving higher performance properties.

By Shannon Wetzel, MetalCastingDesign.com 

Magnesium can take the place of plastic in some end-use applications.

By Frank Goodwin, International Lead Zinc Research Organization Inc., Durham, North Carolina

Operating either as-cast or with an outer coating, zinc die castings can serve in both functional and decorative applications. A relatively dense metal, zinc has a substantial and durable feel. The metal’s hardness, self-lubricating properties, dimensional stability and high modulus make it suitable for working mechanical parts, such as gears and pinions. Zinc also accepts a broad assortment of finishes, from chemical conversion treatments to electroplating and sprayed and baked polymers. When a finish is properly selected and applied to diecast zinc, almost any desired aesthetic can be achieved. Zinc castings can be made to look like solid gold, weathered brass, stainless steel and even leather.

By Shannon Wetzel, MetalcastingDesign.com 

As electricity navigates the jungle of society, copper clears its path. Second only to silver in conductivity, copper makes our reliance on electricity possible. In 2006, an estimated 21,000 tons of copper-base castings were shipped to the electrical industry. Whether it’s a circuit breaker component or a computer part, copper plays an important role in the efficiency of electrical equipment.

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.

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.

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.

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.