Metal Casting

Casting is a manufacturing process where a liquid material is heated to proper temperature (sometimes treated to modify its chemical composition), and is then poured into a cavity or mold, which forms the proper shape during solidification.

Thus, in a single step, simple or complex shapes can be made from any metal that can be melted. The resulting product can have virtually any configuration the designer desires. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.

Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

In addition, the resistance to working stresses can be optimized, directional properties can be controlled, and a pleasing appearance can be produced.

Cast parts range in size from a fraction of an inch and a fraction of an ounce (such as the individual teeth on a zipper), to over 30 feet. Casting has marked advantages in the production of complex shapes, parts having hollow sections or internal cavities, parts that contain irregular curved surfaces (except those made from thin sheet metal), very large parts and parts made from metals that are difficult to machine.

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