Basics of Metal Casting

Metal Casted Parts

Casting: Process in which molten metal flows by gravity or other force into mold where it solidifies in the shape of the mold cavity

  • Oldest shaping processes dating back 6000 years
  • Casting can be used to create complex part geometries (both external/internal shapes)
    o Any material that can be heated to liquid state can be cast
  • Casting capable of producing two forms:
    o Net Shape: no further manufacturing operation required
    o Near Net Shape: Additional shape processing (i.e. machining) required to achieve accurate dimensions
  • Used to produce very large parts (up to 100 tons)
  • Some processes suitable for mass production
    Disadvantages: Limitations on mechanical properties, porosity, dimensional accuracy, surface finish