Automotive Lost Foam Casting
IQ-Enterprises (IQE) specializes in providing quality automotive lost foam casting.
Highly engineered automotive lost foam casting are found in approximately 90 percent of durable goods, including all types of equipment and machinery, cars, trucks, trains, tools, appliances, wind turbines, defense products, weapons, medical products, nuclear plants, hydrants, pipes, oil wells, aircraft and aerospace equipment, toys, art, jewelry, and more.
- aluminum die castings
- zinc die castings
- investment casting
- lost wax casting
- foam casting
- ductile iron casting
- gray iron casting
- malleable iron casting
- shell casting
- resin coated sand casting
- permanent mold casting
- semi-solid metal casting
- and more…
IQE are experts on all types of castings:
China has been using the automotive lost foam casting process for thousands of years. The casting process is when liquid metal is poured into a mold that contains a three-dimensional impression of the intended shape. The metal is then cooled, and the mold removed leaving the “casted” metal part.
Automotive lost foam casting is used for making complex shapes that would not be economical via other methods.
Different casting methods allow for the most economical pricing based on quantities, sizes, materials, and other variables.
Sand casting is for small batches. We can produce these products in small quantities at a low cost. This process allows for small to very large end products. Sand casting also allows most metals to be cast.
Shell molding, also known as shell-mold casting, is an expendable mold casting process that uses resin covered sand to form the mold. It has better dimension control. It is similar to sand casting; the difference is the molding cavity is formed by a hardened shell instead of sand. It uses finer sand mixed with a resin which is molded into a shell. Because the sand is finer and mixed with resin it has a fine surface finish. This process is good for small to medium sized castings made out of cast iron, aluminum, magnesium, and copper alloys.
Investment casting (also known as lost-wax casting in the art world), is the oldest known metal forming technique. This casting process is where the pattern is surrounded with refractory material. The key benefits are versatility, accuracy, repeatability, integrity, and the wax can be reused. It is not as inexpensive as other casting methods; however, it can incorporate intricate contours and the end components are near complete, so they require little or no rework once cast.
Die casting tooling cost is higher than sand or permanent casting, however the part cost is lower. This method forces molten metal under high pressure into the molds (which are machined out of dies). This process is especially good for applications where many small to medium-sized parts are needed with a lot of detail, a fine surface quality, and dimensional consistency is needed.
Permanent mold casting uses reusable molds “permanent molds”. Common casting metals are aluminum, copper alloys, magnesium tin, zinc, and lead alloys. Permanent molds last more than one casting but still do wear out and need to be replaced with long-runs.
Centrifugal casting is when metal is poured into the mold and allowed to solidify while the mold is rotating. Due to the inertial force, the liquid metal gravitates tow the periphery. This process allows 30 to 50 pieces per hour to be produced, with a batch processing of approximately 9000 kg total mass with an average item limit of 2.3 to 4.5 kg.
Continuous casting is for high-volume production. Molten metal is poured into an open-ended, water-cooled mold, which produces a “skin” of solid metal to form over the liquid center. Gradually solidifying the metal from the outside in. Cast size can range from a few millimeters thick strip to approximately five meters wide strip, or small billets to large slabs. This process is good for steel, copper, aluminum, and lead.
Our casted parts are used by industries-leading international companies such s Emerson and Toshiba, as well as small to medium size companies all around the world. Any company looking to reduce costs with their parts manufacturing can benefit from our expertise and services.
Contact IQE for your automotive lost foam casting in-depth consultation to ensure you have the right casting method that is best for your end product needs. We will help reduce your manufacturing costs, save you time, and ensure the fastest turnaround time with the highest quality products.
We provide large parts automotive lost foam casting services in Illinois, Indiana, Kentucky, Ohio, Michigan, Missouri, Iowa, Wisconsin, and the rest of the Midwest. We provide small parts prototype and short run casting services everywhere.