Lost wax casting can manufacture cast steel valve components, such as stainless steel, carbon steel, and other cast steel alloys. The Lost wax casting is a method for valve casting to achieve various suitable tolerances and different smoother surface dimensions.
Stainless steel casting valve parts are widely used in silica sol casting, another lost wax method. We can use this molding process for butterfly valves, ball valves, etc.
- Lost Foam Casting:
This Valve casting technique is a lot appropriate for creating exactitude forged iron valve components and achieving an open surface end and size.Net or nearly net shape castings do not need machining or just a little machining tolerance.
- Sand Casting:
Sand casting is appropriate for each steel and iron valve casting. Compared with lost foam and wax castings, making more significant valve components is more convenient, so we will usually have to leave more machining tolerance for later machining operations. The maximum weight we can throw is around 2 tons per piece.
The Technology Used in Valve Investment Casting Process-
Each of our valve body molding processes is carried out according to Standard Operating Procedure (SOP). The primary valve body molding method of valve body molding production is as follows: casting simulation, mold development, staple review, wax pattern, shell preparation, metal casting, cleanup and processing thermal, inspection, warehouse picking, and shipping.
- Mold Development
The technical department develops the mold, and the quality department uses the three coordinates to carry out the dimensional control.
- Metal Casting
Four sets of 500 kg ovens are in production, and three sets of spare 500 kg ovens are ready when capacity increases. Operators perform rigorous testing to meet hardware requirements.
- Clean and Heat Treat
The workshop has 1 central shot blasting machine, 3 quenching furnaces, 8 heat treatments, and 11 big shot blasting machines.
- Inspection
All rough dimensions are verified using a CMM. We have a Rockwell hardness machine, dynamic balance instrument, roundness meter, etc. The company’s quality department has employees certified to perform UT, PT, MT tests.
The Technology Valve Sand Casting Process-
Each of our valve body molding processes is carried out according to Standard Operating Procedure (SOP). The primary valve body casting process is as follows: casting simulation, mold development, raw material inspection, modeling (coring), smelting, metal casting, cleaning, and heat treatment, assessment, warehouse packing, and shipping.
- Mold development
Design and turn out molds in step with the wants of the drawings. Generally, wooden molds can be used for one-piece production, plastic and metal molds are made for mass production, and jigs can be made for mass castings. Our mold is a principal product of aluminum.
- Modeling (Core-Making)
Includes modeling (forming the casting cavity with casting sand), coring (forming the interior shape of the casting), and mold adaptation (putting the core in the hole and closing the upper and lower vials). Modeling is a critical process in the valve body molding process.
- Merger
According to the desired metal composition, the chemical composition is appropriate, and therefore the acceptable softening chamber is chosen to melt the alloy material to make a certified liquid metal liquid (including capable composition and fit temperature)
- Metal casting
Pour qualified liquid metal into the sandbox equipped with the mold. The casting step has high safety requirements, and we have strict process control to protect the safety of our employees.
- Clean and Heat Treat
If molten metal is poured in and solidified, the casting sand is removed, and the door and other accessories are removed to form the required cast.
- Inspection
All rough dimensions are verified using a CMM. We have a Rockwell hardness machine, dynamic balance instrument, roundness meter, etc. The company’s quality department has employees certified to perform UT, PT, MT tests.
- Valve Casting vs. Forging
Casting valves use the liquid form of metal to create new valves. Many of the metals are melted into a molten liquid, and it is poured into different molds. Once the liquid cools and solidifies, it is broken or ejected from the mold.
One of the most significant advantages of molding is creating valves with complex shapes, patterns, and sizes. Using a mold to make different devices gives you more freedom to make various other valves with more different difficult parts.
Valve Casting is also a powerful, cost-effective solution for many businesses. Valve Casting uses more types of metals and alloys to make various valves. Since it doesn’t like several labors as valve formation, casting helps scale back machining prices, mainly when valves are made with advanced shapes.
