Metalcasting

Metal casting, an ancient process gradually evolving from art to technology for thousands of years, then another 100-year long jump to applied science serves as a backbone to several economies, especially the manufacturing industry. Every other enterprise is savouring the fruit of its products, the most influential ancient industrial process known to form metal shapes.
Have you ever wondered how the manufacturing of the tools or car parts you regularly use occurs? 90% of the goods used daily are a product of the same casting process. Whether it be trail wheels, automobile parts, bus pedals, lamp posts or appliances, metal casting caters to all these goods. These shapes are formed by emptying the molten metal into a mould, where once cooled, the metal extraction from the mould starts.
What does the process involve?
Although it sounds easy-peasy, it’s not. It involves numerous steps, with each requiring a meticulous and skilled job. Let’s walk through the process step by step;
- Pattern Making: A pattern refers to a replica of the casting's exterior, made of metal, wood, plaster or plastic. Patternmaking is significant for the production of industrial parts due to the calculations and precision required for a perfect fitting and operation.
- Core Making – an extra metal piece or sand, also known as the core, moulds the interior to open a cavity if the cast is hollow. Usually, the core removal is convenient after the casting completion as they are solid but collapsible.
- Moulding: metal casting is a process, and typically understanding them doesn't come easy. Imagine yourself strolling on the sea or beach close to the water to create a vision in your mind. You'd notice all the footprints you left behind; here, your foot is serving as the core, and the left print is your foot mould. Moulding is based on numerous steps forming the cast surrounding the pattern with moulding sand. Frame known as a flask contains the mould in casting. The moulding sand (also called Green Sand) fits in the flask surrounding the replica; it is called sand metal casting. After tightly stuffing the sand, while the cast remains, the pattern is removed.
- Melting Metal and Pouring: after melting the metal, the next step is shifting it into a mould cavity and waiting for it to cool down. After it's solid, it's time for some shakeout. The mould goes through vibration to clean the casting of sand. The process completes here with the removed sand for future use and a clean cast.
- Cleaning: the final step marks the removal of the metal product from the mould. The object fettling begins with its cleaning of rough edges, and any leftover material calls the end.

Application in diverse sectors
- Household: Fittings, appliances, furniture, kitchen and gardening equipment
- Machine Tools: extrusion, forging, casting, plastics moulding, and Machining
- Heavy Machinery or tools: farming, mining and construction
- Transport: Aerospace, Automobile, shipping and railways
- Electrical Equipment Machines: Generators, motors, compressors, and pumps
- Art Objects: furniture, sculptures, lamp stands, decorative items and idols
- Defence: Supporting equipment, vehicles, storage, munition, and artillery
- Plant Machinery: Petroleum, chemical, steel, paper, textile, thermal plants and sugar
- Hardware: Valves, pipes, fittings, and joints
Metal casting has benefited the world with its products for centuries. Every product that you look at has one way or the other gone through metal casting.