Metal casting is a process in which a
solid is melted by heating to a proper temperature, and the molten metal
is then poured into a mould or cavity, which helps it to get a proper
shape during its solidification. In this process, simple or complex
shapes can be formed using any metal that can be melted. The finished
components can have virtually any shape and configuration depending on
the design. Moreover, in metal casting process one can improve the
resistance to working stresses of the components. You can also control
the directional properties and a pleasing appearance of the output can
also be achieved.
Size of cast parts varies from a fraction of an inch and a fraction of
an ounce to over 30 feet (10 meters) and many tons, depending on its
application. Metal casting has its advantages over other processes in
the production components, where:
- Parts are having hollow sections or internal cavities
- Parts that contain irregular curved surfaces
- Parts made from metals that are difficult to machine.
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Metal casting is widely used and one of the most popular
manufacturing processes, because of the advantages mentioned above.
It's now almost impossible to think of a design that can't be casted
using available casting processes. But for optimum results and cost
effectiveness, the designers should understand all possible options
before making the final design and use it in the most efficient manner.
Metal casting processes differ mainly in the material used for making
moulds, i.e. sand, metal, etc., and the method of pouring molten metals,
i.e. gravity, vacuum, low pressure, or high pressure. All these
processes focus on some common requirement:
- The solidifications take place in such a manner that would
maximize the desired properties.
- Prevent potential defects, such as shrinkage voids, gas porosity,
and trapped inclusions.
