Introduction: The conventional metal casting processes sometimes fails to satisfy the demands of automotive and other industries. In such situation different methods are combined to form a hybrid casting process. For instance, the foundries find it difficult to cast thin-section as specified for automobiles using conventional methods. Therefore they use a hybrid casting process than include cold box, no bake and shell molding techniques to manufacture thin walls that are dimensionally accurate.

Casting Process : One of the hybrid casting process for the casting of thin wall casting using ferrous metals is a follows:

In this hybrid casting process no bake, shell molding and breadbox are combined with the techniques of firing the mold before pouring as in investment casting. Molds and cores are made using cold box, nobake and shell process where organic binder are used. Now, the molds are dipped in an inorganic binder which seeps into the pores of the mold. When the mold is fired the organic cores and binders are burned off and inorganic binder takes its place. Permanent mold are also used is hybrid castings.

Hot molten metal is poured into the mold when the mold is still hot. Since, the the metal is poured into the mold immediately after the binder has change from the organic to the inorganic material, the mold is further cured and strengthened. And, the chances of forming gases during the process is eliminated. The cooling and the cast removal process is as in the regular form. In this method the use of robots and computer-controlled manufacturing systems can be done.

Application : Hybrid casting process is used for casting process like casting thin section for automobile industry.

Advantages:

• Dimensional accuracy for the castings
• Improved pouring and gating techniques than conventional methods
• High metallurgical quality products.