Steel castings have a variety of end-use applications that require a heavy-duty component. These castings are used in parts for railroad cars, pumps and valves, heavy trucks, construction and mining equipment and power generation equipment. A good steel casting application can provide strength while utilizing a flexible geometry inherent with the metalcasting process.
Steel castings offer high mechanical properties over a wide range of operating temperatures. Further, cast steel offers the mechanical properties of wrought steel and can be welded to produce multi-piece parts as well as large structures.
Design Influence
The metalcasting process offers freedom of geometry allowing casting design to play a key role in mechanical performance. Sections of a cast part subject to higher stress can be enhanced while low-stress regions can be reduced. This flexibility can help cast a part with optimum performance and reduced weight, both of which minimize cost. It is feasible to cast any geometry, but this may increase cost.
When in the preliminary design stages, it can be advantageous to work with a metalcasting facility. Metalcasters have the technical expertise to assist with the casting design and material selection.
To develop a good casting, first reduce the number of isolated heavy sections because junctions within a casting should be designed not to add mass. When working with metalcasters, datum points should be stated, and machine stock should be added to required locations. Section thickness in a casting should be changed through smooth, easy transitions, which can be achieved by adding taper and large radii. Draft should be added to the design dimensions, but metal thickness must be maintained. The amount of draft recommended under normal conditions is 1.5 degrees. Further, reducing undercuts and internal geometry help minimize cost. The metalcasting facility and customer also should agree upon tolerances because specifying as-cast tolerances is important in minimizing cost. Other post-processing details, such as machining and how the part will be held in a fixture, also influence the final cost of the part.
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