In metalworking and jewelry making, casting is a process in which a liquid metal is delivered into a mold that contains a negative impression of the intended shape. The metal is poured into the mold through a hollow channel called a sprue. The metal and mold are then cooled, and the metal part is extracted. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.
Metalworking is the process of shaping and reshaping metals in order to create useful objects, parts, assemblies, and large scale structures. As a term, it covers a wide and diverse range of processes, skills, and tools for producing objects on every scale: from huge ships, buildings, and bridges, down to precise engine parts and delicate jewelry.
A moldmaker or molder (moulder) is a skilled tradesperson who fabricates molds for use in casting metal products.
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand — known as casting sand — as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. In 2003, over 60% of all metal castings were produced via sand casting.
Compression molding is a method of molding in which the molding material, generally preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured; this process is known as compression molding method and in case of rubber it is also known as 'Vulcanisation'. The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms.
Lost-foam casting (LFC) is a type of evaporative-pattern casting process that is similar to investment casting except foam is used for the pattern instead of wax. This process takes advantage of the low boiling point of polymer foams to simplify the investment casting process by removing the need to melt the wax out of the mold.
Rotational molding involves a heated mold which is filled with a charge or shot weight of the material. It is then slowly rotated, causing the softened material to disperse and stick to the walls of the mold forming a hollow part. In order to form an even thickness throughout the part, the mold rotates at all times during the heating phase, and then continues to rotate during the cooling phase to avoid sagging or deformation. The process was applied to plastics in the 1950s but in the early years was little used because it was a slow process restricted to a small number of plastics. Over time, improvements in process control and developments with plastic powders have resulted in increased use.
Spin casting, also known as centrifugal rubber mold casting (CRMC), is a method of utilizing inertia to produce castings from a rubber mold. Typically, a disc-shaped mold is spun along its central axis at a set speed. The casting material, usually molten metal or liquid thermoset plastic, is then poured in through an opening at the top-center of the mold. The filled mold then continues to spin as the metal solidifies.
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.
This article is a list of terms commonly used in the practice of metalworking – the science, art, industry, and craft of shaping metal.
In casting, a pattern is a replica of the object to be cast, used to form the sand mould cavity into which molten metal is poured during the casting process. Once the pattern has been used to form the sand mould cavity, the pattern is then removed, Molten metal is then poured into the sand mould cavity to produce the casting. The pattern is non consumable and can be reused to produce further sand moulds almost indefinitely.
DISAMATIC is an automatic production line used for fast manufacturing of sand molds for sand casting. This process is often used to mass manufacture metal castings for the automotive and machine industries.
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. 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 time 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. Heavy equipment like machine tool beds, ships' propellers, etc. can be cast easily in the required size, rather than fabricating by joining several small pieces. Casting is a 7,000-year-old process. The oldest surviving casting is a copper frog from 3200 BC.
Foundry Products Operations was a subsidiary operation of the Cincinnati Milling Machine Company (CMM), a company which no longer exists. Some parts of the company evolved into the present Milacron, Inc. and Cincinnati Machine. CMM relied heavily on castings for the manufacturing of its machine tool products. The castings were produced at Cincinnati foundries owned by CMM and at foundries independent of CMM, between 1907 and 1988.
Cast iron pipe is pipe made predominantly from gray cast iron. It was historically used as a pressure pipe for transmission of water, gas and sewage, and as a water drainage pipe during the 17th, 18th, 19th and 20th centuries.
Centrifugal casting or rotocasting is a casting technique that is typically used to cast thin-walled cylinders. It is typically used to cast materials such as metals, glass, and concrete. A high quality is attainable by control of metallurgy and crystal structure. Unlike most other casting techniques, centrifugal casting is chiefly used to manufacture rotationally symmetric stock materials in standard sizes for further machining, rather than shaped parts tailored to a particular end-use.
American Cast Iron Pipe Company is a manufacturer of ductile iron pipe, spiral-welded steel pipe, fire hydrants, and valves for the waterworks industry, and electric-resistance-welded steel pipe for the oil and natural gas industry. Headquartered in Birmingham, Alabama, American's diversified product line also includes static castings and high performance fire pumps.
Bremen Castings, Inc (BCI) is a 4th generation family owned manufacturer of machined complete gray & ductile iron castings for heavy truck, valves & pipe fittings, pump components, compressors, lawn/garden equipment, and military contract work. BCI is headquartered in Bremen, Indiana.
Solid Concepts, Inc. is a custom manufacturing company engaged in engineering, manufacturing, production, and prototyping. The company is headquartered in Valencia, California, in the Los Angeles County area, with six other facilities located around the United States. Solid Concepts is an additive manufacturing service provider as well as a major manufacturer of business products, aerospace, unmanned systems, medical equipment and devices, foundry cast patterns, industrial equipment and design, and transportation parts.
