spacer.png, 0 kB
Advertisement
spacer.png, 0 kB
Home arrow Metalcasting Basics
Metalcasting Basics

Metalcasting is a manufacturing process in which metal is melted and poured into molds where it solidifies into geometrically complex components. Metalcasting is unique among metal component forming processes for a variety of reasons.  pouring013.jpg

First, the array of available metalcasting processes are capable of producing very simple to extremely complex components in almost any metal, ranging in weight from less than an ounce to several hundred tons. In addition, metalcasting processes are available that make it economical to produce a single prototype part, while others achieve their economies in creating millions of units.

In terms of value and volume, metalcasting ranks second only to sheet steel, which begins by casting steel slabs, in the metal producing industry. According to U.S. Department of Commerce statistics, metalcasting remains one of the ten largest industries when rated on a value-added basis. Annually, more than 2,000 metalcasters produce 13 to 15 million tons of castings valued at $35 to 40 billion (according to 2008 statistics).

The key to metalcasting design and purchasing comes down to understanding the metal-process marriage.



Guide to Metalcasting Processes Print E-mail
Understanding the metalcasting basics can help you design for manufacturability and utilize processes that meet your specific requirements.

The fundamental process of metalcasting consists of five basic elements:

• Molding—The mold cavity must be formed from a material that will withstand the operating temperatures and conditions of the chosen casting process and metal.
• Pouring—The molten metal is poured into the mold and travels through its passages to fill the mold cavity.
• Solidification—During the solidification process, the metal cools and becomes a solid shape.
• Mold Removal—The cooled casting is removed from the mold.
• Secondary Operations—The casting is trimmed, cleaned, heat-treated, machined, inspected, painted, etc.

Read more...
 
Iron Alloys Print E-mail

Iron castings are produced by a variety of molding methods and are available with a wide range of properties. Cast Iron is a generic term that designates a family of metals. The six types of cast iron are gray iron, ductile iron, compacted graphite iron (CGI), malleable iron, white iron and alloyed iron.

Read more...
 
Steel Alloys Print E-mail

Steel castings have a variety of end-use applications that require a heavy-duty component. These castings are used in parts for railroad cars, pumps and valves, heavy trucks, construction and mining equipment and power generation equipment. A good steel casting application can provide strength while utilizing a flexible geometry inherent with the metalcasting process.

Read more...
 
Aluminum Alloys Print E-mail

Cast aluminum components are used for many functions, from decorative home-owner components, such as lighting fixtures, to highly engineered, safety-critical components for aerospace and automotive applications.

Read more...
 
Copper Alloys Print E-mail

Cast copper alloys are known for their versatility. They are used in a wide range of applications, such as plumbing fixtures, ship propellers, power plant water impellers and bushing and bearing sleeves, because they are easily cast, have a long history of successful use, are readily available from a multitude of sources, can achieve a range of physical and mechanical properties and are easily machined, brazed, soldered, polished or plated.

Read more...
 
Magnesium Alloys Print E-mail
Cast magnesium alloys have gained popularity in recent years due to their ability to maintain high strengths at light weights. Magnesium possesses unique properties that can open the door to important markets for structural applications and has gained widespread use in automotive components. Further, non-automotive applications, spurred on by the computer, electronics and power tool industries, continue to expand.
Read more...
 
Diecast Zinc Alloys Print E-mail
While traditionally focused in automotive, hardware and plumbing markets, diecast zinc alloys have become an alternative material of choice in consumer product industries such as communications, electronics and home appliances.
Read more...
 
Spotlight On: Metalcasting Documentary Print E-mail

The documentary Spotlight On: Metalcasting was produced by AFS and aired nationally on PBS. The five-minute documentary provides an overview of metalcasting and the importance cast components play in our society.

 

Read more...
 
Casting Terms Print E-mail
Browse through our glossary for definitions of common metalcasting terms.
Read more...
 
spacer.png, 0 kB
spacer.png, 0 kB
spacer.png, 0 kB
spacer.png, 0 kB
spacer.png, 0 kB