Being one of the oldest manufacturing techniques that still survives today, casting is the process in which a molten liquid is poured into a cast to achieve a desired shape. After the molten liquid harden, the cast can be taken away and the end product which can also be referred to as a casting is sent to be polished and distributed. The reason for this ancient technique being able to survive up to the present can be because of the need for metal customization or economical setup. Casting is more economical than having to shape items by hand or other methods. The most common type of casting in the industry today is for metals. In this article I would not be concentrating on castings of other sorts besides metal.
The process of casting starts with a mould that is going to shape the molten metal being created. As moulds are manufactured in foundries, manufacturers develop designs of mould that relate to the final casting product they would want to achieve and take them to the foundries. Casters then develop the desired moulds that manufacturers want. Thereafter comes the melting down of the metal that is to be shaped. The melting process also takes in the foundry. The liquefied metal is poured into the cast or mould with the help of machines and equipments. These machines can also monitor the rate at which the metal is poured into the cast as to avoid overflowing. The metal is then left to cool and once it has hardened, the cast can be removed for the metal to be cleaned.
The application of metal casting is done for products that require identical, precise and complex shaped products. As a mould can be reused over and over again, a manufacturer can create several products that look exactly the same. Also molding metals by hand into complex shapes would not be as economical to manufacturers as casting as them would require extra man power and equipment. If some metals require precise detail, molding can ensure that as well. Some manufacturers nowadays make use of machinery to shape the mould precisely so that it can capture details and imprint them onto castings.
Although the job may sound to be quite easy, it is not a simple task after all. Casters have to be aware that there are impurities in the air and they might be present inside where the metal is being cast or on the mould itself. Impurities can mix with the molten metal and as it hardens will solidify within the metal. This would affect the quality of the casting and eventually may even cause it to break. The molten metal has to be poured into the mould carefully to avoid any air bubbles. If the bubbles were to be trapped inside the casting as it hardens, the casting would not be of best quality and may break easily. The caster must take note that the poured liquid metal does not harden immediately so he would not have any problem pouring it slowly and carefully. This is to ensure that the casting is of the best quality.