Creating the casting blueprint, defining gating channels, parting lines, and risers. Mold cavities are then prepared from sand, permanent metal, or ceramic shells depending on the required precision and production volume.
Steel is melted in a furnace, such as an electric arc furnace or induction furnace, to achieve the required chemical composition and temperature. Precise control is essential to avoid defects like porosity or segregation.
The molten steel is carefully poured into the prepared mold through the gating system. Proper flow and temperature management are critical to ensure complete filling and minimize turbulence, which can cause defects.
The steel solidifies in the mold, forming the final shape. Risers and chills help control the cooling rate to prevent shrinkage cavities and ensure uniform microstructure.
Once solidified, the casting is removed from the mold. Sand or investment residues are cleaned off, and excess metal from gates and risers is removed. This step prepares the casting for inspection and finishing.
Castings may undergo heat treatment, machining, grinding, or surface finishing to achieve the required mechanical properties, dimensional accuracy, and surface quality.