Casting is a manufacturing process in which liquid material is poured into a space or cavity, which is usually made of metal and is then allowed to cool and solidify. The solidified part, or casting, is then removed from the mold, usually a pattern, and the process is complete. Castings are widely used in the automotive, aerospace and marine industries, as well as in the production of other products.
There are numerous types of casting processes, ranging from traditional die-casting, to modern centrifugal and vacuum casting methods. The most common method of casting is sand casting, which involves the use of sand and a pattern to form the desired shape of the product. Sand casting can be used for a variety of different materials, including aluminum, brass, copper, and steel. The sand is mixed with a binder and compressed in the mold, which can be either permanent or expendable.
In addition to sand casting, centrifugal casting is also a popular type of casting that can be used to produce parts and components with a high level of accuracy and repeatability. This type of casting involves the use of a centrifugal force which is applied to the liquid material before it is poured into the mold. The centrifugal force generates a spinning motion which helps to evenly distribute the feedstock into the cast.
Vacuum casting, also known as lost-wax casting, is a process used to create intricate and complex parts with a high degree of accuracy. The process begins with a pattern, usually made of wax or a similar material, which is then immersed into a bath of liquid plastic. The plastic is then heated and the pressure inside is controlled, so that the plastic is able to fill the contours of the pattern. The pattern is then removed, allowing the cast to be separated from the plastic.
Finally, die-casting is a manufacturing process in which molten metal is forced into a mold cavity under extreme pressure. This type of casting is often used to create parts with high dimensional accuracy and uniform wall thicknesses. Die-casting is typically used for production of smaller parts since it is more cost effective than other methods of casting.
Casting is used to create parts and products with a high degree of accuracy, repeatability, and strength. Whether the part is created through sand, centrifugal, vacuum, or die casting, these processes all supply their own unique advantages. As new materials and advancements in technology continue to become available, it is certain that casting will continue to play an important role throughout numerous industries.
