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Metal Casting Process Explained

building metal casting

Manufacturers commonly use castings to build complex metal components with precise dimensions. Castings can take many different forms and sizes, depending on the application and specifications. In this article, we’ll go through the rich history of metal casting and the process of creating these valuable devices.

learning about metal casting

What is Metal Casting?

The Rich History and Evolution of Metal Casting

Metal casting is arguably the earliest and most influential industrial process in history. It’s used to make many metal objects used in our daily lives: train wheels, lamp posts, school bus pedals, and more. Over the centuries, the processes have evolved and modern foundries rely on metal recycling as a cost-efficient source of raw material, significantly reducing wasted scrap metal that might end up in landfills.

The oldest known metal casting is a copper frog, which is said to have been made in Mesopotamia about 3200 BCE. Around 700 BCE, China created the first cast-iron manufacture. However, the essence of the method has stayed largely the same.

Metal Casting: The Process

Pattern Making

Pattern making requires precise calculations to make pieces fit and work together. A pattern is a replica of the exterior of the casting; it is typically made out of wood, metal, plastic, or plaster.

Core Making

Additional sand or metal (referred to as a core) is used to sculpt the interior shape of a hollow casting. Cores are typically robust but collapsible, making it simple to remove them from the completed casting.

Molding

Molding sand is used in a multistep procedure to produce a cast around the pattern. A mold is enclosed in a frame known as a flask, and molding sand is placed into the flask during casting.

Melting and Pouring

After melting the metal, it is poured into the mold hole and left to settle and solidify. The shakeout process follows in which the molds are vibrated to remove sand from the casting.

Cleaning

The cast metal item is taken from the mold and fettled in the final cleaning phase. The object is cleansed of any molding material, and rough edges are eliminated during the fettling.

creating metal casting

Want To Know More About Metal Casting?

At Ferralloy Inc., our team is comprised of experts with decades of experience in the industry. We utilize the latest technology combined with proven methods to deliver products quickly without sacrificing quality. Contact us for a quote today!