Casting Process

 Casting Process, Advantages of Casting, Limitations of Casting, Applications of Casting

Foundry:

• Casting is probably one of the most ancient processes of manufacturing metallic components.

• With few exceptions, it is the first step in the manufacture of metallic components.

The process involves the following basic steps:

• Metal casting process begins by creating a mould, which is the 'reverse' shape of the part we need.

• The mould is made from a refractory material [eg: Sand] with help of pattern [eg: Wood]

• The metal is heated in a furnace until it melts.

• The molten metal is poured into the mould cavity.

• Allowing the molten metal to cool and solidify in the mould.

• Removing the solidified component from the mould.

• The solidified piece of metal, which is taken out of the mould, is called as “Casting”.

• A plant where the castings are made is called “Foundry”.

• The word “Foundry” is derived from a Latin word “fundere” meaning “melting and pouring”.

Mould, molten metal and Patterns

Mould:

• It is a hollow cavity of casting, made up of moulding sand.

• Moulding sand is natural sand or synthetic sand.

• Pattern is kept in the moulding sand to prepare mould.

Molten metal:

• The semi solid state of meta] is known as the molten metal.

• For this the solid metal is heat in furnace above it’s recrystalisation temperature.

• Cast iron, aluminum are melted in various furnaces to get them in semi solid state.

Patterns:

• Pattern is a template to produce mould cavity.

• Patterns are made of light materials like wood, plastic.

Advantages of foundry (Casting):

• It is cheapest manufacturing process.

• It is very fast.

• Intricate shapes can be produced.

• No wastage of material.

• Suitable for mass production.

Limitations of foundry (Casting): 

• Only suitable for materials with castability such as cast iron aluminum and its alloys, gold . 
• Needs furnace to produce molten metal .
• Usually casting are brittle and not too tough.

 

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