What is casting? Getting to know the steps, types and applications

What is casting

Casting is the process of producing different parts using molten metal materials and special molds. These materials, which after freezing, are used in various industries; As far as we can see its footprint as the mother industry everywhere. From the production of a half-millimeter zipper to the construction of multi-ton parts of ocean-going ships, all are done with the help of casting processes.

This industry, which is more than 8000 years old, has evolved over time and today it is made in different ways. Such as sandblasting, centrifugal casting, precision casting, etc. are possible. Stay with us to continue this article to tell you what casting is and what its uses, benefits and steps are.

Melting metals to get the desired piece is a process with a history of thousands of years. The date of the beginning of human use of its processes is generally considered to be something between 5 and 8 thousand years ago; The period when mankind had reached the stage of mastery in the use of metals. However, today's changes in the process of shaping metals date back to the 1800s. Also, after recognizing the advantages of using nickel metal for steel production, metallurgical knowledge was developed. Centrifugal method, which was invented in 1809, is one of the new methods of this industry.

The starting point of the metal forming process is to create a 3D model of the part. These models are generally made using materials such as wax, polymers, foam, wood or aluminum. A modeling for the part must follow principles such as modeling slope, alloy shrinkage factor and amount of machining required.

Permanent: Metal molds that can be reused.
Disposable: Disposable molds made of materials such as sand, plaster or ceramic shell. They will be.

By combining different elements, alloys can be created, each of which has different characteristics. According to the expected features for the part, you should choose the best alloy for it. Among the widely used iron alloys, we can mention steel, steel, and all kinds of cast iron. For more information, you can refer to the steel casting price article, which is dedicated to steel alloy. In the table below, we have introduced some different alloys to you.

In the alloying stage, experts must be familiar with the appropriate temperature of the melting process for optimal melting of each alloy. The use of induction furnaces in this process ensures more homogeneity of the alloy. On the other hand, electric arc furnaces can also be used to alloy some cast iron grades. Gas and ground furnaces are also used in melting non-ferrous alloys.

This step means the same process of transferring molten material and directing it into the mold. At this stage, protective clothing and various safety tools are used to ensure the safety of workers. Note that if the parts are thin or small, the melt must have a higher temperature. Of course, you can also use preheated pot or pan.

The step of discharging the mold is one of the steps in which the mold must be cooled enough to be able to remove the part from it. The type of template has an impact on the continuation of the process and determining the actions of this stage. This step can include removing the part from the mold with tools such as hammers, hammers, and shakers, as well as cutting using air cutters or grinding stones.

The finishing stage includes the use of methods and devices for cleaning the part. For example, with non-ferrous alloys, sandblasting can be used, and for ferrous alloys, shot blasting can be used to remove sand and clean.