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Casting, Forging


Various casting processes are among our capabilities. These range from traditional gravity casting (coquille casting) to low-pressure gravity casting through lost-wax casting to the more developed forms of automatic processes. All available for the most common types of materials. Forging is also among our capabilities.


Coquille casting
A permanent metal mould is used, consisting of two or more parts that fit together, the cavities of which correspond to a model of the object to be moulded. The piece cast using the corresponding casting system must be “self-discharging” so as to be able to get the casting out of the metal mould.

The coquille is made from cast iron blocks, using various machining operations. The service life of the mould is determined by the size of the product, its shape and its complexity.

Before proceeding to casting, ‘coatings’ must be applied. For different parts of the coquille, different types of coatings are used to locally stimulate or retard solidification.

Advantages of coquille casting:

  • The availability of a permanent mould. This avoids high raw material costs, such as in ‘sand casting’ and precision casting, where for each new casting a new mould needs to be made.
  • The casting has good dimensional accuracy.
  • Relatively low investment compared to high-pressure casting.
  • An environmentally friendly production technique.

Disadvantages of coquille casting:

  • Limited freedom of shape for the mould compared to sand casting.
  • Sufficient wall thickness is required in comparison with injection moulding.
  • Relatively difficult to automate.
  • Particularly suitable for small to medium-size runs.


Lost-wax casting (also known as investment casting)
Is a method for casting precision parts on an industrial scale in metal casting alloys with a high melting point. Lost-wax casting is the most accurate of all the casting processes and in which post-processing will be limited to a minimum.

The strong points of lost-wax casting:

  • Great freedom of shape for the mould.
  • Possibility of casting complex shapes. Consequently, assemblies (screwed, welded, etc.) can be avoided and weight can be saved.
  • Little post-processing is necessary, which yields a considerable reduction in the cost of production.
  • Good surface condition (Ra. = ± 3.2 µm).
  • Limited investment in tools, so that this casting method can also be used for smaller production runs.

Applications: Lost-wax casting is very widely applicable in almost all branches of industry (Food, Automotive, Marine, Piping, Machine building, Tools, Engines, Agriculture, Defence, Aviation, Construction hardware, etc...).


Forging
Is a hot shaping method which differs from casting. In forging, the steel is made pliable in a furnace and then pressed into a steel mould which consists of two parts. This method of production does not allow for core cavities to be made. A forged part is thus always solid. This is a limitation of forging relative to casting.

An advantage of forging over casting, however, is that it is considerably cheaper than casting, for example, in cast steel if good welding properties are desired.