Challenges to the US Metal Casting Industry

Source : Metal Casting Company

Metal casting is one of the oldest and most important industrial sector of United States. The industry was first established in 1642 in the US and since then has helped the country to become the world’s most admired industrial nation in manufacturing, science, defense, medicine and aerospace. Fundamental to the America’s economy, metal casting continues to play an important role in the success of US manufacturing through the production of quality castings. As a matter of fact, metal castings are today used in 90% of all manufactured products in the United States.

However, today the US metal casting industry is facing many challenges as never before. The industry is facing the most intense global competition in its history and is severely affected by the increasing costs associated with regulations and other actions by the government, energy prices and health care.

Some of the major challenges to the US metal casting industry are –

Economic Slowdown – Slowdown in economy has resulted in slowest manufacturing recovery in decades. This recession has caused significant job losses and numerous foundry closures.

Foreign Competition – Most of the competitors to the US metal casting industry are free from complex regulations, high labor costs, and enjoy subsidies and government trade protections.

Government Regulations – Several government regulations are badly affecting the US metal casting industry. The most immediate and threatening regulation at this time is EPA’s Iron and Steel Foundry MACT. This regulation is expected to be more onerous, expensive and damaging to the future of American metal casting industry.

Energy – The US industry is facing tough challenges with rising energy costs. The industry needs government support for improved efficiency, infrastructure and investments in new technologies.

Posted By : C.I.Casting

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The good and bad things about the cast iron garden bench

Source : Varun Metal Foundry

The good and bad things about the cast iron garden bench

In this world, everything is dictated by balance, a harmonious relationship between all things, and everything having a negative counterpart. Love has hate, happiness has sadness, and optimism has pessimism. Likewise, everything has pros and cons.

The cast iron garden bench is no exception.

Cons

1. It is heavy.

The cast iron bench is anything but lightweight. It is extremely heavy, and it is difficult to move it around. For this reason, this bench is not suitable for those people who rearrange their furniture often. They would struggle with this and aside from the rearrangement; they would also get unnecessary back pains.

2. It is rare.

Most furniture companies do not manufacture this anymore, because they rarely use cast iron now. However, this is not necessarily a bad thing. It is a good thing for those people who are into antique furniture collection. Those people like the thrill of looking for and finding rare collectibles.

3. It has a cold feel to it.

The cast iron bench is uncomfortable to sit on, since it has a cold, even lumpy, feel to it. Although there are some variations of this where the seat is made of wood and other materials, most are still made of cast iron.

Pros

1. It is versatile.

The cast iron garden bench can be used in a lot of places and can fill in a lot of functions. It can be used as general seating, day beds and picnic seating.

2. It is inexpensive.

Need I say more?

3. It is easy to clean and maintain.

The cleaning of the cast iron bench would only require materials that can be found at home. The maintenance is convenient as well. Unlike other types that would require polishing, this bench only needs to be painted once in a while.

4. It is long-lasting.

The cast iron bench has a light finish that allows it to be places outside all year long. It can withstand harsh conditions like the heat of the sun, rain, snow, hail and mist. This is because it is made of strong and durable materials.

5. It is attractive.

It can be utilized as the perfect accent to your garden or home. Cast iron can easily be soldered and molded to any design, so there are a lot of designs available on the market. It also gives off a feeling of calmness, so it is the perfect place to relax and meditate in.

Check C.I.casting company latest website over at http://www.varunmetalfoundry.com which gives people advice about the best Cast Iron Process as well as more information on C.I.Casting.

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An Introduction to Sand Casting

Sand casting is the most common technique used around the world. A typical process flow of sand casting is shown in the following diagram: 
Sand Casting
Sand is used as a refractory material in sand moulding systems. Sand casting process is a binder maintains the shape of the mould while pouring molten metal. There is a wide range of sand/binder systems that are used in sand casting system. Bentonite clay is used upto 4-10% of the sand mixture in Green sand systems, which is the most common sand casting system. Water, which makes up around 2-4% of the sand mixture, activates the binder. Carbonaceous material such as charcoal (2-10% of total volume) is also added to the mixture to provide a reducing environment. It helps in preventing the metal from oxidizing while pouring. The remaining 85-95% of the total mixture contains sand.

A range of chemical binders is used by other sand moulding processes: Oil binders are mixture of animal oils, petrochemicals and vegetable. Some of the popular synthetic resin binders are: ureaformaldehyde, phenolics, phenolformaldehyde, urea-formaldehyde/furfuryl alcohol, alkyl isocyanate and phenolic isocyanate. Chemical resin binders are frequently used for foundry cores and less extensively for foundry moulds.

Varun Metal Foundry is the leading manufacturer of C.I. CastingGray C.I. Casting,Close Gray C.I. Casting, and Graded C.I. Casting

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An Introduction To Investment Casting

Source : Varun Metal Foundry

Investment casting is also called lost wax casting. Lost wax process was used by the ancient people dated back to 5000 years. Now, investment casting keeps the principles of old method ,but applying the latest technology to meet the exacting demands of modern industry.

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In every industry where metal components are used, investment castings can offer advantages – to the production engineer, designer, or buyer, especailly where complex shapes are required.

There are many  advantages of investment casting :

Investment casting can eliminate most rough machining operations;

Give greater freedom of design;

Produce shapes that are impossible to machine;

Provide lighter and clearner looking components;

Relieve production problems by replacing assemblies with “one piece” castings;

Widest choice of casting material.

For more of investment casting advantages and how it can help you realize your design, please visit www.varunmetalfoundry.com

Posted By : C.I.Casting Company

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An Introduction to the Casting Molds

Posted By : Varun Metal Foundry

Metal casting is generally a manufacturing process wherein a liquid material is emptied into a mold, which comprises a hollow opening of the desired form or shape and is then allowed to solidify. This solidified casting is then removed and broken out so as to complete the procedure.


While sand is used as the primary mold material, there is a metal that is used as the mold. Typically, a cast meehanite or iron is used as the mold material and sand is used to make the objects. The cavity surface is usually covered with a thin layer of material (either sodium silicate or clay), which is heat resistant.

Usually the casting molds are pre-heated to a temperature of about 3920 F before the metal is pored into the cavity. The design of cavity for these casting molds does not works on the same principle of shrinkage like in sand casting molds. This is due to the fact that casting molds heat up and enlarge during the pouring process and hence the cavity does not require to be expanded as in the case of sand castings. However, care should be taken so as to ensure a right balance as people may use an external source of water for cooling or they may also opt for appropriate radiation techniques.

Varun Metal Foundry is the leading manufacturer of C.I. CastingGray C.I. Casting,Close Gray C.I. Casting, and Graded C.I. Casting

Posted by : C.I.Casting 

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Close gray C.I. Casting at varun metal foundry

Posted by : Varun Metal Foundry

Close gray C.I. Casting At Varun Metal Foundry every furnace heat is measured for carbon content by thermal analysis and the carbon content is adjusted to meet target levels. By carefully adjusting carbon content, Varun Metal Foundry casts a wide range of gray iron as specified by Standard Specification for Gray Iron Castings.

Since gray iron tensile strength and machinability is also controlled by the casting section thickness, the ability to adjust chemistry in small furnace heats is the key to short leadtime casting of small and large castings. We can melt several chemistry programs in a single day with our fast melt induction furnaces, shortening leadtimes for all our castings.

Posted By : C.I.Casting 

 
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Cast Iron Casting at Varun Metal Foundry

Source : C.I. Casting

C.I. Casting Cast iron is an iron, carbon and silicon alloy that has been melted and poured into a mould to form a shape. The Chinese developed furnaces for making cast iron around 500 BC. These furnaces were hot enough to melt cast iron so that it could be poured into moulds to make many products including weapons, jewellery and cast iron cookware.The structure of cast iron, which is graphite flakes in a relatively pure iron matrix, has several useful properties. Firstly, the metal expands slightly on solidifying as the graphite precipitates, resulting in sharp, well defined castings. The graphite content also offers good corrosion resistance, particularly when compared to mild steel. Graphite acts as a lubricant, improving wear resistance.Typical Applications for Cast Iron Castings:

  • Engineering Castings
  • Heavy Engineering Plant & Equipment
  • Original Equipment Manufacturers
  • Petrochemical & Oil Production Sector
  • Aerospace Applications
  • Shipping Construction
  • Transportation Infrastructure & Railway Stock
  • Mining, Quarrying & Minerals
  • Energy Sector & Power Production
  • Hydro Applications
  • Pump & Valve Manufacturers
  • Rolling Mills & Steel Production
  • Special Engineering Cast Iron Castings
  • Architectural Castings
  • Decorative Castings

Posted By : Graded C.I. Casting

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Products from varun metal foundry

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C.I.Casting Company

Source : C.I.Casting

Varun Metal Foundry is engaged in manufacturing of C.I. CastingGray C.I. CastingClose Gray C.I. CastingGraded C.I. Casting. We are producing 150 M.T. of good castings per month. 

Our casting supply is to textile industry for their indigenous and export requirement as well as Automotiveand Engineering Industry
We supply casting of different kinds under the strict quality norms, our systems at work have become fail-safe to produce and maintain quality of the castings and standards as continuous process. 
With the advent of liberal Economic policy of the Govt. of India, large investments are being made by the Indian industries to cater market requirements. 
We are constantly on the move to improve and maintain our quality. Our strength has been our personnel and we are sure we can provide the best of quality castings at all time. This will result in additional business opportunity to our customers and us. 
Today we offer our clients a complete solution for their requirements under one roof at M/s. Varun Metal Foundry

We deliver on time and with quality, that is our motto at “Varun” and assurance of quality is never compromised.

Posted By : Graded C.I. Casting

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Major Cast Metals – Characteristics & Applications

Source : Metal Casting India

Although a variety of metals are used in metal casting, the major ones are Grey Iron, Ductile Iron, Aluminum, Steel and Copper Base. These cast metals are listed below, with their percentage usage, characteristics and applications – 

Grey Iron 

  • Use – 54%
  • Characteristics – Heat resistance, damping, economical, low shrinkage and high fluidity.
  • Applications – Automobile cylinder block, clutch plate, brake drum, housings and machine tool beds.


Ductile Iron

  • Use – 54%
  • Characteristics – Strength, wear & shock resistance, machinability and dimensional stability.
  • Applications – Crank shafts, cam shafts, valves, brackets, rollers and differential housing.


Aluminum

  • Use – 12%
  • Characteristics – Strength to weight ration & corrosion resistance.
  • Applications – Oil & fuel pumps, automobile pistons, clutch housings and connecting rods.


Steel 

  • Use – 9%
  • Characteristics – Machinability, weldability and strength.
  • Applications – Machine parts, valves and gears.


Copper Base

  • Use – 2%
  • Characteristics – Corrosion resistance and high ductility.
  • Applications – Valves, marine impellers and hydraulic pump parts.

Varun Metal Foundry is the leading manufacturer of C.I. CastingGray C.I. Casting,Close Gray C.I. Casting, and Graded C.I. Casting. Its workforce including administrative staff and engineering staff, Varun Metal Foundry manufactures cast iron of various grades confirming to national and international standard suitable for high temperature and pressure application as per drawings, patterns and samples. 
We at Varun Metal Foundry believe in commitments, we make to our customers of quality and service each with best efforts.
Looking Forward To a Professionally Fruitful Business Association.

Posted By : Graded C.I.Casting

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