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