Metal Casting Information and Basic Metal Casting Information

By: Kent Klein

Casting can be defined as a process ofmanufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’containing a desired shaped hollow cavity, and then made to solidify. Theejection or breaking out of the casting then takes place to get the processcompleted. The use of casting is ‘forming hot liquid metals’ or numerous metalsthat are cooled after having the components like clay, plaster, concrete, andepoxies mixed. Complex shapes are normally made by casting, as other methodsare not feasible. Casting came into being around 6000 years ago. ‘Copper Frog’is the most ancient casting existing till date since 3200 BC. The process ofcasting has two distinct subdivisions: non-expendable and expendable moldcasting.

‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous,centrifugal, die, and permanent casting.

Continuous casting: Continuous casting can be defined as a refined process of casting forhigh-volume, continuous production of ‘metal sections’ with constantcross-section. The pouring of molten metal into a water-cooled, open-endedcopper mold takes place. This allows a ‘layer’ of ‘solid metal’ to be formedabove the ‘still-liquid’ center. Continuous casting is widely accepted due toits cost-effectiveness. The metals continuously cast are aluminum, copper, andsteel.

Centifugal casting: Centrifugal casting is independent of both-pressure and gravity. Thisis because its own ‘force feed’ is created by the way of using a ‘temporarysand mold’ in ‘spinning chamber’ at 900 N. Lead time is variant with respect toapplication. True- and semi-centrifugal processing allow 30 to 50 pieces/hr.The batch processing has an upper limit of around 9000 Kg (practically). Thismethod used to be applied for ‘Casting of Railway Wheels’. It was developed bythe company called ‘Krupp’. It had a German origin. Jewelry is normally cast bythis method.

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Die-casting:Die casting can be defined as a process of ‘forcing molten metal’ intocavities of mold under high pressure. These castings comprise of nonferrousmetals, especially-alloys of aluminum, copper, and zinc. It is even possible tomake die castings of metal. The method of die casting is used where finer partsare needed.

‘Permanent Mold Casting’:This casting is made up of non-ferrous metals. It requires some time toset up (some weeks), after which the production rate of about 5 to 50 pieces/hour-moldis achieved. The coating of ‘acetylene soot’ is applied to steel cavities. Thishelps in removing the work piece easily and promoting longer life (of tools).Permanent molds possess a limited life span. For worn molds, replacement orrefinishing is required.

Expendable mold casting: ‘Expendable Mold casting’ can be referred to as a standardclassification inclusive of the following:

Sand casting: It is amongst the simplest and most popular casting types used sinceages. It involves very small size operations. The bonding of sand takes placeby use of clays (as in ‘green sand’) or ‘polymerized oils’, or ‘chemicalbinders’. Recycling is easily possible.

Plaster casting (for metals): There is no difference between plaster casting and sand casting, exceptthe fact that plaster is used in place of sand. SimilarlyPsychology Articles, there are alsoplastic and concrete castings.

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