We are Manufacturer, Supplier, Exporter and Dealer of Cast Basalt, Cast Basalt Cylinder, Cast Basalt Tiles, Cast Basalt Bends, Cast Basalt Lined Pipes. Our setup is situated in We are Manufacturer, Supplier, Exporter and Dealer of Cast Basalt, Cast Basalt Cylinder, Cast Basalt Tiles, Cast Basalt Bends, Cast Basalt Lined Pipes. Our setup is situated in jamshedpur, jharkhand, India. India.
Cast Basalt is produced by melting of naturally available basalt rock and cast into tiles and cylinder. The casting is so produced is then subjected to heat treatment cycle to produce Re – crystallized basalt the resultant product is called as fused cast basalt which has excellent wear resistant properties against sliding and friction induced abrasion and also inherits the inertness of parent material.
1. Introduction
Metal Casting is one of the oldest and most widely used manufacturing processes, where molten metal is poured into a mold cavity and solidified to obtain a desired shape.
It allows the production of complex shapes, large components, and near-net-shape products.
First practiced ~6000 years ago, it remains the backbone of automobile, aerospace, machinery, construction, and tool industries.
2. Technologies Included
a) Conventional Casting Processes
Sand Casting – Uses sand molds; versatile, economical.
Shell Molding – Sand + resin molds; better accuracy.
Die Casting – Molten metal injected into steel dies under pressure.
Investment Casting (Lost Wax) – Wax pattern coated with ceramic; excellent precision.
Permanent Mold Casting – Reusable metal molds for medium-size batches.
Centrifugal Casting – Molten metal poured into rotating mold; good for pipes, rings.
b) Advanced / Modern Technologies
Vacuum Casting – For aerospace alloys.
Continuous Casting – Used in steel plants for billets/slabs.
Squeeze Casting – Combines casting & forging.
3D Sand Printing + Casting – CAD-based mold making.
3. Applications
Automotive Industry – Engine blocks, cylinder heads, crankshafts.
Aerospace – Turbine blades, structural components.
Construction – Pipes, manhole covers, fittings.
Machine Tools – Beds, housings, gears.
Consumer Goods – Cookware, decorative items.
Defense – Gun parts, missile components.
4. Remarks
Best suited for complex shapes, heavy components, and mass production.
Material wastage is low compared to machining.
Accuracy depends on process (sand casting less accurate, investment casting highly precise).
Foundry operations can be labor-intensive and energy-consuming.
5. Standard Operating Procedure (SOP)
a) Pattern & Mold Preparation
Select suitable pattern material (wood, metal, wax).
Prepare mold (sand, ceramic, or steel).
Provide allowances (shrinkage, machining, draft).
b) Melting & Pouring
Melt metal in furnace (cupola, induction, arc, crucible).
Control composition and temperature.
Pour into mold under gravity/pressure/vacuum.
c) Cooling & Solidification
Allow controlled cooling (avoid shrinkage defects).
d) Shakeout & Fettling
Break mold, remove casting.
Cut off risers, runners, gates.
Clean by shot blasting/grinding.
e) Inspection & Finishing
Dimensional check, NDT (X-ray, ultrasonic, magnetic particle).
Heat treatment or machining if required.
6. Site Parameters (Selection Criteria)
Metal Type → Steel, iron, aluminum, copper, magnesium.
Casting Size → Few grams (jewelry) to several tons (ship propellers).
Tolerance Required → Sand casting (low), investment casting (high).
Production Volume → Sand (low cost, low qty), die casting (high volume).
Cooling Conditions → Affect grain structure & properties.
Infrastructure → Foundry space, furnaces, ventilation
7. Safety Features
Operator Safety
PPE: heat-resistant gloves, face shields, aluminized suits.
Proper training in handling molten metal.
Process Safety
Ventilation to remove gases/fumes.
Slag removal and dross handling.
Fire extinguishers & emergency exits.
Environmental Safety
Dust collection systems.
Waste sand recycling.
8. Quality Features
Mechanical Properties → Hardness, tensile strength, elongation.
Dimensional Accuracy → Depends on process.
Surface Finish → Ra values vary (sand ~12 µm, die casting ~2 µm).
Defect-Free Casting → Minimize porosity, shrinkage cavities, cold shuts.
Inspection & Testing → Visual, dimensional, radiographic, ultrasonic, hardness.
9. Cost Parameters
Initial Cost → Low for sand casting, high for die/investment casting (due to tooling).
Material Cost → Metal + additives (fluxes, binders).
Energy Cost → Furnace operations = major expense.
Labor Cost → Pattern making, mold prep, fettling.
Maintenance → Furnace lining, mold reuse.
Life-Cycle Cost → Economical for bulk production, expensive for prototypes (unless using 3D printed molds).
