Ferrous Materials: Iron & Steel
- Grey Iron Castings are generally used on applications that do not need the mechanical characteristics of Ductile Iron. This casting technology is generally cheaper than Ductile Iron because the base material is cheaper than Ductile Iron.
- Ductile Iron is generally used on parts that require higher mechanical characteristics than that of Grey Iron. These typically include fatigue and stress type applications, engine mounts and FEAD brackets.
- High Silicon Moly (HiSiMO) – This type of iron is used in high temperature applications such as exhaust components. It is very good at remaining structurally sound at higher temperatures.
Non-Ferrous Materials: Aluminum & Alloys
- Sand Casting – Typically used on parts that have internal passages and range in volume from 1 to under 50,000 pcs per year depending on part complexity. This process yields a higher piece but a lower up front tooling investment than Semi-Permanent Mold.
- Semi-Permanent Mold – Same casting criteria as Sand Casting but this casting technology is typically used in higher volume production because it incorporates a steel mold. Piece prices are generally lower than sand casting but tooling investment is higher than sand casting.
- Gravity/Low Pressure Die Casting – This process is used where strength is high concern. The alloy of choice on this is 356 Aluminum and typically has a heat treatment added as well. Volumes on this can range from medium to high volume. Piece price is typically lower than Semi-Permenent Mold but tooling is generally higher.
- High Pressure Die Casting – This process is used when no internal cores are present in which the passages make turns inside the casting. Volumes on this casting technology are typically higher than 50,000 pcs per year. This process yields lower piece prices but high tooling investment.