Metal Casting
Metal casting is a fundamental manufacturing process that involves pouring molten metal into a mold cavity to create a desired shape upon solidification. This ancient technique has been instrumental in shaping the development of tools, machinery, and structures throughout human history and remains a cornerstone of modern industrial production. It allows for the mass production of complex metal parts with a high degree of accuracy and efficiency.
The metal casting process begins with the creation of a mold, which can be either reusable or expendable, depending on the method employed. Expendable molds, such as sand molds or investment molds, are destroyed after each casting, whereas permanent molds, typically made of metal, are used repeatedly. The mold includes a cavity that reflects the final shape of the part, along with channels for pouring and venting the metal. Molten metal is then introduced into the mold, allowed to cool and solidify, and finally removed and cleaned to produce the final cast product.
There are several types of metal casting methods, each suited to different applications, production volumes, and material requirements. Sand casting is one of the most widely used methods due to its versatility and low cost. It involves packing sand around a pattern to form a cavity, which is then filled with molten metal. This technique is ideal for large components and short production runs. Die casting, on the other hand, uses high pressure to force molten metal into a steel mold, resulting in parts with excellent surface finish and dimensional accuracy. It is commonly used for high-volume production of components made from non-ferrous metals like aluminum, zinc, and magnesium.