Metal Casting

Metal casting as production processes is usually done by sand casting and die casting. Both processes required making molds, melting metals, performing casting processes, and finishing achieved castings. While die casting is a costlier project, Die casting operations are carried out in special die casting machines usually done for bulk production and sand casting is by far the most widely used casting process and cost-efficient to run small production.

Casting metals like Iron, Brass, Aluminium begins with the mold. The mold contains a cavity whose geometry determines the shape of the cast part. The actual size and shape of the cavity must be designed slightly oversized to allow for shrinkage that occurs in the metal during solidification and cooling. Different metals undergo different amounts of shrinkage, so the mold cavity must be designed for the particular metal to be cast if dimensional accuracy is critical. Molds are made of a variety of materials, including sand, plaster, ceramic, and metals. The various casting processes are often classified according to these different types of molds. To accomplish a casting operation, the metal is first heated to a temperature high enough to completely transform it into a liquid state. In an open mold, the liquid metal is simply poured into the mold as soon as the molten metal is in the mold, it begins to cool. When the temperature drops sufficiently to the freezing point of a material, Once the casting has cooled, it is removed from the mold. After that, trimming the excess metal from the actual cast part so that all sharp or extra metal is removed, and the surface is clean and smooth.