Casting

History and Types of Casting

• Metal casting has been used throughout history to make tools, weapons, and religious objects.
• Metal casting originated in Southern Asia, specifically in China, India, and Pakistan.
• Southern Asia traditions and religions heavily relied on statue and relic castings made from a copper alloy laced with lead.
• The majority of castings in early civilizations were simple one to two piece molds made from stone or ceramics.
• The lost wax process, which originated in ancient Mesopotamia, allowed for more intricate designs in castings.
• Casting is a manufacturing process that involves pouring liquid metal into a mold.
• Metal casting is the most common type of casting in metalworking.
• Plaster, concrete, and plastic resin can also be cast using molds.
• Resin casting is a method used for casting plaster, concrete, or plastic resin.
• Different materials and treatments can be used to give the appearance of metal or stone in plaster or concrete castings.

Metal Casting

• Metal casting involves heating metal until it becomes liquid and pouring it into a mold.
• The mold includes the desired shape, as well as runners and risers to allow the metal to fill the mold.
• The solidified part, or casting, is recovered from the mold and excess material is removed.
• Metal casting is commonly used in the production of various metal objects and components.
• It is a versatile and widely used manufacturing process in metalworking.

Fettling

• Fettling is the process of removing irregularities and unwanted bits from raw castings.
• It involves cutting, grinding, shaving, or sanding the castings.
• Fettling can add significantly to the cost of the final product.
• Robotic processes have been developed to automate some parts of the fettling process.
• Designers of molds aim to minimize fettling through mold shape and material selection.

Casting Process Simulation

• Casting process simulation uses numerical methods to predict cast component quality.
• It considers mold filling, solidification, cooling, and mechanical properties of the casting.
• Simulation helps in designing the casting system and optimizing energy, material, and tooling usage.
• Commercial software programs are available for casting process simulation.
• It is regarded as one of the most important innovations in casting technology in the last 50 years.

Lost-Wax Casting

• Lost-wax casting has a long history dating back to ancient times.
• The early history of lost-wax casting can be traced back to South Asia.
• Adriaen de Vries, a renowned sculptor in bronze, played a significant role in the development of lost-wax casting.
• Lost-wax casting was also practiced in Bronze Age China.
• Lost-wax casting has been used to create various types of artifacts and sculptures.
• Lost-wax casting involves creating a wax model, encasing it in a mold, and then melting the wax to create a cavity.
• Different materials can be used for the mold, such as plaster or ceramic.
• The molten metal is poured into the mold and allowed to cool and solidify.
• The mold is then broken or removed to reveal the final cast object.
• Lost-wax casting allows for intricate and detailed designs to be reproduced accurately.
• Lost-wax casting is commonly used in the production of jewelry and decorative objects.
• It is also used in the creation of sculptures and artworks.
• The automotive and aerospace industries utilize lost-wax casting for the production of complex metal components.
• Dental prosthetics and medical implants can be manufactured using the lost-wax casting process.
• Archaeologists and historians rely on lost-wax casting to replicate and study ancient artifacts.
• Lost-wax casting allows for the production of highly detailed and intricate designs.
• It offers a high level of accuracy and repeatability.
• The process can accommodate a wide range of materials, including various metals and alloys.
• However, lost-wax casting can be time-consuming and labor-intensive.
• Large-scale production may require additional steps and equipment.
• Computer-aided design (CAD) and analysis have revolutionized the lost-wax casting process.
• Advanced technologies, such as 3D printing, have been integrated into the casting industry.
• Research and development efforts are focused on improving the efficiency and sustainability of the lost-wax casting process.
• New materials and alloys are being explored to expand the applications of lost-wax casting.
• Collaborations between artists, engineers, and scientists are driving innovation in the field of lost-wax casting.

Casting Data Sources