Sand Casting |
Advantages | Disadvantages | Recommended Application |
Least Expensive in small quantities (less than 100)
Ferrous and non - ferrous metals may be cast
Possible to cast very large parts.
• Least expensive tooling | Dimensional accuracy inferior to other processes, requires larger tolerances
Castings usually exceed calculated weight
Surface finish of ferrous castings usually exceeds 125 RMS | Use when strength/weight ratio permits
Tolerances, surface finish and low machining cost does not warrant a more expensive process |
Permanent and Semi-permanent Mold Casting |
Less expensive than Investment or Die Castings
Dimensional Tolerances closer than Sand Castings
Castings are dense and pressure tight | Only non-ferrous metals may be cast by this process
Less competitive with Sand Cast process when three or more sand cores are required
Higher tooling cost than Sand Cast | Use when process recommended for parts subjected to hydrostatic pressure
Ideal for parts having low profile, no cores and quantities in excess of 300 |
Plaster Cast |
Smooth "As Cast" finish (25 RMS)
Closer dimensional tolerance than Sand Cast
• Intricate shapes and fine details including thinner "As Cast" walls are possible
• Large parts cost less to cast than by Investment process | More costly than Sand or Permanent Mold-Casting
Limited number of sources
Requires minimum of 1 deg. draft | Use when parts require smooth "As Cast" surface finish and closer tolerances than possible with Sand or Permanent Mold Processes |
Investment Cast |
Close dimensional tolerance
Complex shape, fine detail, intricate core sections and thin walls are possible
Ferrous and non-ferrous metals may be cast
As-Cast" finish (64 - 125 RMS) | Costs are higher than Sand, Permanent Mold or Plaster process Castings | Use when Complexity precludes use of Sand or Permanent Mold Castings
The process cost is justified through savings in machining or brazing
Weight savings justifies increased cost |
Die Casting |
Good dimensional tolerances are possible
Excellent part-part dimensional consistency
Parts require a minimal post machining | Economical only in very large quantities due to high tool cost
Not recommended for hydrostatic pressure applications
For Castings where penetrant (die) or radiographic inspection are not required.
Difficult to guarantee minimum mechanical properties | Use when quantity of parts justifies the high tooling cost
Parts are not structural and are subjected to hydrostatic pressure |