CPM Industries' Blog

Castings Found on a Vehicle

Posted by Gavin Mason

Metal Castings on your Vehicle

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Tags: Aluminum Castings, Magnesium Castings, Aluminum Sand Casting, casting, castings, diecasting, metal castings, cast iron, aluminum, magnesium

Price Per Pound: Sand Castings

Posted by Gavin Mason

Analyzing Costs 

Analyzing costs in the metalcasting industry is completely different in comparison to other industries. Analyzing costs in the metalcasting industry depends on so many different variables that makes it nearly impossible to design two parts that cost the same. Even if the two parts are identical dimensionally, chances are there may be a difference in price. It may seem as simple as total man hours + cost per pound of material = suggested price, but there is so much more than that. We will start with the overall weight of the casting, overall weight plays a big roll in cost, but it also has some variables. There are many different materials and metal alloys to choose from when it comes to casting and each of those materials have their own price. So two castings may have the same exact design to perform the same exact task with one being made of aluminum and the other cast iron. Iron weighs more than aluminum so the cast iron part will obviously weigh more than the aluminum one, but it will cost less. Why? 

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Tags: Aluminum Sand Casting, sand casting, Cast Iron (Gray) Sand Casting, Tips for Buying Sand Castings

Does Your Casting Have a Sweet Tooth?

Posted by Gavin Mason

Simple Sugar may Solve Complex Problem 

The foundry and metal casting industry is a multi-billion dollar industry with foundries of all shapes and sizes located throughout the world. Metal castings can be dated back to before the Roman empire and were used to develop weapons and tools as well as being critical in the development of human civilization. The most common method of casting is known as sand casting and involves using sand to hold the shape of a part. Once the sand is in the shape of the part to be casted, molten metal is poured into the sand mold forming the final part. If you are like me, the first time I heard of this process my first question was, "so how does the sand stay in place with molten metal being poured into it?" 

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Tags: Casting Design, Aluminum Castings, Sand Casting Design Improvements, Aluminum Sand Casting, Green Sand Casting Method, Prototype Sand Castings, Quality Control of Sand Casting, sand casting, Magnesium Sand Casting, casting

Cast vs. Billet

Posted by Gavin Mason

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, CPM Industries, casting, CNC, Aluminum Hog-Outs, Billet

Designing Tips for Heavy or Large Castings

Posted by Tim Carlstedt

   I wanted to take some time to discuss some aspects that need to be considered with Large, Heavy Castings.   We are going to provide some tips and discuss our thought process when working with these Large Sand Castings

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Tags: Aluminum Sand Casting, Ductile Iron Sand Castings, Cast Iron (Gray) Sand Casting, Large Sand Castings, Large or Heavy Sand Castings

What is a Rapid Prototype Aluminum Casting?

Posted by Tim Carlstedt

What is the difference between a Rapid Prototype Aluminum Casting versus an Aluminum Hog-Out?  Also, why would you choose one over another?  Well let’s clarify what each is:

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Tags: Aluminum Castings, Aluminum Sand Casting, Prototype Sand Castings, Aluminum Hog-Outs, Rapid Prototype Castings, Rapid Prototype Aluminum Castings

Aluminum Sand Castings: Foundry vs. Finished Casting Supplier

Posted by Tim Carlstedt

  One determination that all Aluminum Sand Casting buyers must consider is whether their project is best suited to be manufactured at either an Aluminum Foundry or a Finished Aluminum Casting Supplier.  There are a lot of little aspects that go into this decision such as: Quantity, Delivery Time, Material, Machining Capabilities (if necessary), and (for obvious reasons) Quality.  So, let’s distinguish the difference between the two supplier options. 

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Tags: Aluminum Castings, Aluminum Sand Casting, Green Sand Casting Method, Turn-Key Sand Cast Components, Aluminum Sand Castings

Benefits of Aluminum Sand Castings?

Posted by Tim Carlstedt

Ever wonder what makes Aluminum such a popular choice for sand castings?  While there are a ton of factors that go into that decision, here is a list of the 6 reasons why Aluminum is chosen for so many different applications.

    1. Low Density

      1. Weighs 1/3 of Steel
    2. Good Conductor of Electricity

    3. Non-Combustible  and Non-Magnetic

      1. These traits are excellent and make the alloy invaluable for projects that involve electronics
    4. Non-Toxic

    5. Malleable/Ductile

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Tags: Aluminum Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Tips for Design Sand Castings

Sand Casting vs. Investment Casting

Posted by Tim Carlstedt

What are the advantages and disadvantages between the Green Sand Casting Method and the Investment Casting Method?

This is a common question for the metal casting industry and CPM wanted to shed some light on the subject.  In this entry, we will first look at a comparision of the two different methods, followed by a explanation of the table, then lastly another table highlighting the advantages and disadvantages of each method in comparison.

 

Comparison of Green Sand Casting vs. Investment Casting

 

Green Sand Casting Method

Investment Casting Method

Relative Cost in Quantity

Low

Highest

Relative Cost for Small Number

Lowest

Medium

Permissible Weight of Casting

Unlimited up to approx. 1 ton

Ozs to 100 lbs.

Thinnest Section Castable (Inches)

1/10

1/16

Typical Dimensional Tolerance (Inches)

.012

.01

Relative Surface Finish

Fair to Good

Very Good

Relative Mechanical Properties

Good

Fair

Relative Ease of Casting Complex Design

Fair to Good

Best

Relative Ease of Changing Design in Production

Best

Fair

Typical Base Tolerances

+/- .040 – 1.00 in

+/- .003 - .008 in

Typical Surface Finish

150 – 350 RMS

63 – 125 RMS

Minimum Wall Thickness

.140 - .250 in

.094 - .187 in

Typical Tooling Cost

$800 to $5,000

$3,000 to $10,000

Well, WHAT DOES THAT MEAN TO ME?!

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Secondary Machining, Finished Surfaces, Prototype Sand Castings, Pattern/Foundry Tooling, Patterns for Sand Castings, Cast Iron (Gray) Sand Casting, Investment Casting Method

Ranking Machinability of Sand Castings

Posted by Tim Carlstedt

    Machining a Sand Casting is a major cost contributor in a project that involves a finished casting. The major factors to in determining Machinability are the alloy's hardness (meaning softer is better), how long the cutting tool will last, and time it takes (includes labor) to complete all the operations in machining. 

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Secondary Machining, Cast Iron (Gray) Sand Casting

CPM Example: Finished (Machined) Aluminum Casting

Posted by Tim Carlstedt

Want to see another example of CPM's capabilities? 

Pictured below is a Finished (Machined) Pipe made from an Aluminum Sand Casting for the Automotive Industry.  Our processes allowed us to take this project from start to finish in order to provide the customer with a part that was ready for testing.  To go into the process a little more, CPM was given a solid model, from which we designed and manufactured the pattern with necessary cores, got the castings, and fully machined it so it was ready to go for assembly!

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Tags: Aluminum Castings, Aluminum Sand Casting, Secondary Machining, CPM Industries' Example

Common Pouring Temperatures for Sand Castings?

Posted by Tim Carlstedt

    We have provided a quick reference tool depicting the general pouring temperatures for Zinc, Aluminum, Copper, Iron, and Steel.  The differences in pouring temperature of a liquid metal can affect casting costs through the power requirements to reach the target temperature and the expense of the respective furnace to do so.

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Tags: Ductile Iron Sand Casting, Steel Sand Casting, Cast (Gray) Iron Castings, Aluminum Sand Casting, Green Sand Casting Method

Sand Casting vs. Other Casting Methods

Posted by Tim Carlstedt

    There are several methods that are used to produce a casting.  But what are the general differences and characteristics of the Methods?  Here is a table that represent that highlights the key differences between the Green Sand, Precision Molding, and Chemically Bonded Molding casting methods. 

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Cast Iron (Gray) Sand Casting, Magnesium Sand Casting

A CPM Example: From CAD Model to Finished Aluminum Sand Casting

Posted by Tim Carlstedt

A Look into CPM's Turn-Key Capabilities for an Finished Aluminum Sand Casting!

    We were recently asked to show an example of a Turn-Key Cast Component that we have made here at CPM Industries.  So, why not share it with the world!  What does Turn-Key mean to us?  This means that the project will go from Engineering Assistance, Pattern Tooling, Casting, and Secondary Machining.  We also perform any other additional testings that may be required.

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, Casting Wall Thickness, CPM Industries, Secondary Machining, Finished Surfaces, Pattern/Foundry Tooling

Aluminum Plaster Casting? What is that?

Posted by Tim Carlstedt

  Recently, I was asked to describe what Plaster Casting was and the benefits of using this method.  What a perfect topic!  At CPM, we provide Aluminum Plaster Castings primarily to Simulated Die Casting in Short Runs of 15-30 for Prototyping and Testing Operations. For runs of 1 or 2 parts, then it is often best to go with a Rapid Prototyping such as a SLA.

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, Simulated Die Casting, Plaster Casting Method, CPM Industries, Casting Knowledge, Prototype Sand Castings, Pattern/Foundry Tooling

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