What is Metal Casting?

Metal casting is a process in which molten metal is poured into a mold with a hollow cavity of a geometrical shape and is left to cool down to make a solidified part. It is used to make complex or large parts that are difficult or expensive to manufacture. It is a modern process but with ancient roots. Metal casting is the earliest industrial process in history. It is used to make automotive parts, train wheels, lamp posts, school bus pedals, etc.

Metal casting is a cost-efficient method that significantly reduces wasted scrap metal that might end up in landfills. It is a technique that is applied for various purposes, including wear plate and much more.

The Metal Casting Process

1. Pattern Making

Patterns are made of wood, metal, plastic, or plaster. Patternmaking is the most important step for industrial part-making, where you need precise calculations to make all the pieces fit and work together.

2. Core Making

If the caste is hollow then an additional piece of sand or metal helps in shaping the internal form and then makes it hollow. Cores are generally strong yet collapsible so they can be removed with utmost ease from the finished casting.

3. Molding

Molding is a process that forms a cast around the pattern using molding sand. In the casting process, a mold is contained in a frame-like structure called a flask. Greensand, or molding sand, is packed into the flask around the pattern to form a shape. Once the sand is tightly packed you can remove the pattern and the cast will remain intact.

4. Melting and Pouring Molten Metal

After the metal is melted, it is then poured into the cavity of the mold and left untouched so that it can solidify. Once it is solidified the process of shaking out begins.

5. Cleaning

In the final step, the cast metal object is finally removed from the mold and then trimmed accordingly. During trimming, the object is cleaned and the rough edges are removed.

Advantages of Metal Casting

1. The process of metal casting helps you produce complex shapes.

2. Large products can be produced ad one-piece cast using this process.

3. Using this method you can cast almost every material and equipment such as wear plates, pellet press, etc.

4. This process is cost-efficient.

5. It casts difficult or expensive material.

6. You can achieve hollow or internal cavities easily using this process.

What do you need for Metal Casting?

The metal casting process requires different tools and materials. There are various tools and pieces of equipment necessary for metal casting such as mold boxes, crucible tongs, vent wire road, water spray, and hand ramming tools. For example, the vessel which holds the molten metal is called a "crucible."

What is Metal Casting used for?

Metal casting is a very old process that is used in manufacturing both manufacturing and fine arts. Molten metal is finally transferred from a crucible into a mold that creates a positive metal cast object. The metal and mold are cooled down and then the metal object is removed and finished.

What Products are made by Metal Casting?

Steel forging manufacturers also apply metal cast techniques on different products such as pump housing, industrial furnace doors, fire hydrant housing, heat treatment furnace, aluminium gearbox, ring segment castings, etc.

CONCLUSION

There are different types of moulds for different projects you just have to determine your purpose and your wants. You should be very careful while doing this process and make sure you have a well-ventilated workplace, a mould, a crucible, tongs, a torch, a furnace, etc.

If you want to cast a small or complex piece of metal, the possibilities in metal casting are endless. The type of metal casting that you want to choose will depend on the final product. If you are interested in making jewellery then, you will have to work with various precious metals such as gold, silver, and platinum.