Metal Casting

Metal casting can be simply described as pouring molten metal into a mold with a cavity that is identical in shape and size as the desired end piece, and then allowing it to cool and solidify. When the casting is finally removed from the mold the result is often a piece that requires little to no post-production processing. In contrast with the general belief, casting can be considered as a prehistoric technology.

There are examples of cast iron in China from as early as 600 B.C. Currently, metal casting has reached an impressive level as technology has improved both the basic process and the materials. Doubtless, the advantages and properties provided by metal casting stimulated more than enough interest in scientists and engineers, which in turn provided a fast improvement in the process. Some of those mentioned advantages can be summarized as: * Being able to design both internal and external contours independently * Producing a complex part as a single unit * Being able to produce a finished product in one step * Varying shape and size configurations Metal casting in general has a variety of applications, ranging from industrial products to household appliances. Motor vehicles, farm equipments, engines, valves, pipes, pumps, railroad equipment, various hardware, machinery, aircrafts, air conditioning, household appliances and medical equipment are all examples of metal casting end products. Of course, not all of those products can be cast with a single casting process. Some processes have more advantages over others casting processes, and some constructions and products can only be cast with a certain process. One of the most versatile and basic casting process is called Sand Molding, in which the mold is made with specially produced sand mixed with a resin or other binder. Other types of metal casting processes use ceramic, plaster or metal as molds. In terms of technology used, investment casting (or precision casting) is similar to casting with ceramic molding. One significant difference is that a ceramic slurry is applied around a disposable pattern (mostly wax) and then allowed to harden.

The next step is removing the wax inside the hardened mold by heating in furnaces, also known as “lost wax casting”.

The next step is pouring molten metal into the mold, and then breaking the mold after the metal is solidified. Also it's possible to use metal molds in alloy casting, which involves and inserting the molten metal into the cavity under pressure. Another interesting process is known as centrifugal casting. As you can see, casting is a very versatile process, supporting many variations, metals and alloys. Metal casting it used widely all around the world and certainly deserves the reputation it has earned.