The metal casting process is defined as the process in which molten metal, is poured into a mold that contains a hollow cavity of a desired geometrical shape, and allowed to cool down to form solidified parts.
The metal casting process can be divided into two major groups by the basic nature of the mold design. They are:
1. Expendable Mould Casting.
2. Nonexpendable/Permanent Mould Casting.
1. Expendable Mould casting: It's a method that utilizes single-use or temporary mold to produce the final casting, as the mold will be broken to get the cast product out.
The expendable mold is divided into two.
* The permanent pattern * The evaporative pattern.
* The permanent pattern uses a permanent model to create the mold pattern. Examples include Sand casting, plaster mold casting, shell mold casting, and ceramic casting.
* The evaporative pattern uses temporary mold which will evaporate to create the mold pattern. Examples include Lost foam cast and investment casting.
▶ Sand Mould Casting: Sand is used to create the mold.
▶ Plaster Mould Casting: The molding material is made of plaster from Paris.
▶ Shell Mould Casting: Uses resin-covered sand to form the mold.
▶ Ceramics Mould Casting: the mold is made of refractory ceramic material.
▶ Lost Foam Casting method: Uses a polystyrene foam pattern to create the sand mold, which then vaporizes when the molten metal is poured into the mold.
▶ Investment Casting: A wax pattern is coated with a refractory material to make the mold, which is then melted away before pouring molten metal into the mold.
2. Non-expendable or Permanent mold casting: uses a permanent mold that can be reused after each production cycle. Examples include; Pressure die casting, gravity die casting, centrifugal casting, and continuous casting.
▶ Pressure die casting: Molten metal is forced under pressure into a securely locked metal die cavity.
▶ Gravity die casting: The molten metal is poured inside the mold cavity using a ladle or a vessel.
▶ Centrifugal casting: makes use of centrifugal force to fill a mold with molten metal.
▶ Continuous casting: Allows metals and metal alloys to be shaped and then solidified without interruption.
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