What is metal casting? Metal casting process flow

What is casting?

Casting is a technique for manufacturing parts using various metals and alloys. First, the metals and alloys are heated to a high temperature, keeping them in a liquid (molten) state. Then, the molten metal is placed into a mold with a cavity (permanent or disposable), where it cools and solidifies into the predetermined shape. Finally, the casting is removed from the mold, yielding the finished product.

Casting is considered the simplest and most economical process for producing parts of various sizes, specifications, and geometries, from the simplest to the most complex. Therefore, it can produce semi-finished or finished parts. The casting process can also achieve surface finishes through forming, welding, machining, deburring (chip removal), and heat treatment.

Applications: Pipe fittings, engine blocks, cylinder heads, piston rings, machine tool bases, wheels, axles, etc.

The following are the steps in the casting process: 

Mold making: A part model made of materials such as wood, metal, plastic resin, and foam plastic, which can be permanent or non-permanent, is used to give the casting its shape.

Core-making drills: These molds, made of various durable materials, create channels or holes in parts that need to be hollowed out (voided), and can be broken after solidification and cooling to remove the part.

Metal melting: This is the change of state of raw materials from solid to liquid under high temperature (heat), with a melting point of approximately 1530ºC.

Pouring (filling): This is the process of pouring liquid material into the mold cavity and through channels, where the material will wait to cool and solidify.

Demolding: This refers to the process of removing the part from the mold manually or mechanically after it has solidified and cooled.

Finishing (deburring and cleaning): Processing using wire brushes, grinders, sanders, abrasives, cutting tools, and other tools.