The parts in the devices and equipment around us are produced using manufacturing processes. Some of these parts are made on a small scale and others on a large and industrial scale. One of the most well-known industrial manufacturing methods is casting.

Casting is a widely used process for the production of metal parts. This process is highly popular in the automotive and machine manufacturing industries.

In this article, we introduce the principles and concepts of casting. At first, we review the applications, the materials used, the types of implementation methods, the general implementation process, the advantages, disadvantages, and defects of this process.

Next, we’ll explore the history, common terms, and types of casting methods. At the end, we will provide some additional tips and learning resources for this important process.

“Casting” is one of the oldest manufacturing processes, which is done by melting materials and pouring them into a mold. This process is one of the most common methods of manufacturing metal parts in various industries.

Casting provides the possibility of mass production of parts with small to large dimensions, weight of several grams to several tons, simple to complex shape and integrated structure. There are several methods of casting. However, sand casting is known as the oldest and most common casting method.

What is the application of casting?

Casting is used in almost all industries. About 90% of the products produced in various industries and industrial machinery are somehow related to casting processes. However, more than 50% of cast parts are used in heavy machinery and transportation equipment industries.

What are the materials used in casting?

Gray cast iron is the most widely used material used in the casting process. Other common metals in this process include cast iron, aluminum, steel, copper and zinc. Of course, it is possible to use non-metallic materials such as concrete, glass, plastic and resin to make cast parts.

How is casting done?

Although there are different methods for casting, this process usually takes place during several general steps, including pattern making, muscle making, mold making, metal melting, pouring the molten material into the mold, freezing, opening the mold, and polishing the part. The activities in each of these stages are:

Modeling: designing industrial molds used in the casting process by specialized software and making the physical model of the final part
Muscle building: design and build the muscles needed to create the internal surfaces of the part
Mold making: making a casting mold according to the design documentation and using materials such as sand, wax, steel, etc.
Melting and pouring: applying high temperature to metals to become liquid and pouring the molten material into the mold by the crucible or other available equipment.
Freezing: reducing the temperature of the mold and the molten material inside it after the pouring process is finished
Opening the mold: separating different parts of the mold and removing the cast mold part
Finishing: cutting, grinding, sandblasting, etc., in order to remove the excess parts of the part, create the appropriate texture, or prepare its surface for coating.