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Metal casting

A few principles


Through the high performance of its parts, it is always at the forefront in all the major markets (aircraft, space, motor vehicles, energy, chemicals, defence, telecommunications, construction, rail, mechanical industries).
All shapes, practically all alloys, very high mechanical and thermo-mechanical properties, very high dimensional precision, are all readily achievable through casting. There is no limit to the number of parts which may be produced nor, in practical terms, to the weight and size of the parts. Casting enables the production of highly complex geometry single-piece parts or the combination of several functions on a single part. As no metallic parts are beyond its reach, casting is the only solution available in economic and/or technical terms for manufacturing certain parts used especially in leading edge applications.


The metal casting industry is as old as civilisation itself, but remains a leading edge industry: lost wax, pressure die casting, etc.
One might add, and it is far from its least merit these days, that it is the only industry which directly recycles its own waste as well as that produced by other metal conversion industries.

The elaboration of a casting involves the following stages:
  • Preparation of drawings by the prime contractor, preferably in collaboration with the foundry, specifying the dimensional tolerances
  • Design and manufacture of the tooling
  • Pouring
  • Finishing operations
  • Inspection

Pelton wheel cast in Al-bronze

The casting process allows great flexibility in the choice of geometry.
 
The choice of casting alloy is dependent on the properties required: mechanical strength, toughness, low or high temperature resistance, low density, hardness, specific magnetic properties, resistance to abrasion, corrosion etc.

 

Casting is the operation which consists in pouring the molten metal into the die. This can be achieved using various techniques:
  • By gravity, the most commonplace method, using ladles
  • At low pressure or by suction, using sand moulds or metal dies
  • Under high pressure, this is known as pressure die casting (in metal dies)
  • By centrifugation (rapid rotation of a metal die)
  • Under vacuum (investment casting)

A few figures

The foundry sector is part of the intermediate product industry, and as such is located upstream of all the users of metallic parts. Through its industrial sub-contracting activity (85% of turnover in 2004), it supplies all the major industrial sectors. Foundries are increasingly now expected to provide prime contractors with a service in which they undertake the complete assembly of several parts.


The position of french foundries in the world marketplace


In second place in the European Union, French foundries achieved a turnover of 5.3 billion euros excl.-VAT in 2004.

Structures et performances



498 companies


47 000 employees

Their direct exports represent 36% of production, i.e. 1.35 billion euros excl.-VAT.

Their combined commercial profit amount to 0.5 billion € (excl.-VAT).