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Overview of Metal Casting Methods

The casting method was discovered around 3500 BC and involves pouring molten material into a mold to produce components. Casting can produce complex parts in any metal from less than an ounce to hundreds of tons, and is used to manufacture 90% of goods, including automotive, agricultural, and industrial components. Casting offers versatility and economic benefits over other metal forming processes due to its ability to create complex shapes in a cost-effective manner.

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9 views1 page

Overview of Metal Casting Methods

The casting method was discovered around 3500 BC and involves pouring molten material into a mold to produce components. Casting can produce complex parts in any metal from less than an ounce to hundreds of tons, and is used to manufacture 90% of goods, including automotive, agricultural, and industrial components. Casting offers versatility and economic benefits over other metal forming processes due to its ability to create complex shapes in a cost-effective manner.

Uploaded by

Wilson Benneh
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

CASTING METHOD

The casting method was discovered probably around 3500 BC in Mesopotamia. Casting is
unique manufacturing processes for a variety of reasons. Perhaps the most obvious is the
array of moulding and casting processes available that are capable of producing complex
components in any metal, ranging in weight from less than an ounce to single parts weighing
several hundred tons. Foundry processes are available and in use that are economically viable
for producing a single prototype part, while others achieve their economies in creating
millions of the same part. Virtually any metal that can be melted can and being cast. Many
parts and components are made by casting, including automotive components such as
carburettors, engine blocks, crankshafts, agricultural and rail road equipment’s, pipe and
pumping fixtures, power tools, gun barrels and large components of hydraulic turbines etc.
Since 1950, partially automated casting processes have been developed for production lines.
It is estimated that castings are used in 90% or more of all manufactured goods and in all
capital goods machinery used in manufacturing. The diversity in the end use of metal casting
is a direct result of the many functional advantages and economic benefits that casting offer
compared to other metal forming methods. The beneficial characteristics of a cast component
are directly attributable to the inherent versatility of the casting process.

Casting processes involve the use of molten material, usually metal. This molten material is
then poured into a mould cavity that takes the form of the finished part. The molten material
then cools, with heat generally being extracted via the mould, until it solidifies into the
desired shape. Although the above describes a relatively simple process, casting is generally
quite a complex process due to the complex metallurgy of using molten metal. Casting
processes can be broken down into two broad categories
1. Expendable mould processes.
2. Permanent mould processes.
With expendable mould processes, the moulds are destroyed in order to remove the casting.
Typical mould materials include sand, plaster and ceramics mixed with a bonding agent.
However, with permanent mould processes, the mould itself is reused and must therefore be
designed to allow the easy removal of the casting. Typically, permanent mould are made
from metals that retain their strength at high temperatures.
Classification of casting processes.
1. They can produce complex shapes with internal cavities or hollow sections.
2. Many casting processes can produce very large parts.
3. They can process materials difficult to process otherwise.
4. Depending on the lot size, casting may be the most economical method of production.

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