Alloy Steel and Stainless Steel Casting Manufacturing Processes

There are various types of steel and thus, require different methods for casting.  United Global Sourcing has experience working with many of these methods and processes for steel.  When cast iron cannot provide sufficient strength or shock resistance, steel casting is used.

Steel castings are broadly classified into two main groups:

Carbon Steel
Alloy Steel

So what is the difference between the two? Steel, in which the main alloy is carbon, is referred to as carbon steel. In fact, the AISI which is the American Iron and Steel Institute defines carbon steel as “Steel is considered to be carbon steel when no minimum content is specified or required for chromium, cobalt, molybdenum, nickel, niobium, titanium, tungsten, vanadium or zirconium, or any other element to be added to obtain a desired alloying effect; when the specified minimum for copper does not exceed 1.04 percent; or when the maximum content specified for any of the following elements does not exceed the percentages noted: manganese 1.65, silicon 0.60, copper 0.60.”

Steel, which is not stainless steel, is sometimes referred to as carbon steel.

Steel that is alloyed with various different elements is called alloy steel. The various elements range from 1% to about 50% in body weight. These elements are alloyed to increase the mechanical properties of steel. Alloy steel could be low alloy or high alloy, depending on the percentage of alloy. But in general, the term alloy steel means low alloy steel.

Steel is used quite often in everyday life.  From construction of bridges to cooking utensils, steel is utilized often.  For big constructions, predefined shape of steel casting is used. Foundries across the world use a casting process with steel alloy to make the predefined steel shapes. The process in which we get the desired solid shapes is called alloy steel casting process.

Molten metal is poured into a mold and is allowed to solidify within the mold. The mold is then broken, revealing a solid piece. This manufacturing process is called Casting. This process can yield both simple as well as more complex shapes and designs. Diffusion of carbon or alloying elements, softening, hardening, stress relieving, toughening, improve machinability, increase wear resistance, and removal of hydrogen entrapped at the surface of the casting are all brought about by high alloy steel casting.

The method of simulating the casting process was initially developed in the early 70s at universities, mainly in Europe and in the US. Since the late ’80s, there have been commercial programs that enable foundries gain new insight into what is happening inside the mold or die during the casting process.

The simulation process predicts the cast component’s quality up-front. The casting is designed keeping in mind the component properties. This not only reduces the wastage in pre-production sampling, it also predicts the precise layout of the complete casting system thus leading to energy, material, and tooling savings.