CASTING:

It is one of the most ancient process of manufacturing metallic components. It is the first step in manufacturing metallic components.

It can be defined as process of producing metal parts by pouring the molten metal into the mould cavity of the required shape and allowing the metal to solidify. The solidified metal piece is called as ‘’casting’’.

Types of casting:

 

Steps involved in casting:

• Making the pattern of the part with all details.
• Making a mould by packing the sand around the pattern and then removing the pattern to leave a cavity.
• Inserting the cores if required.
• Melting and pouring the molten metal into mould. After solidification casting is removed from the mould.
• Fettling and inspection of casting.
• Further processing (machining and finishing) if required.

Advantages:

1. Parts of intricate shapes can be produced.
2. Almost all the metals and alloys and some plastics can be cast.
3. A part can be made almost to the finished shape before any machining is done.
4. Good mechanical and service properties.
5. Mechanical and automated casting processes help decrease the cost of casting.
6. The number of castings can vary from very few to several thousands.

Disadvantages:

1. Lot of molten metal is wasted in riser and gating.
2. Casting may require machining to remove rough surfaces.
3. Some defects occur in the casting like blow holes, misrun, run out, mismatch etc if casting process not properly followed.