Metal casting is one of the oldest ways of shaping metal. It involves pouring liquid metal into moulds, allowing it to set, and then removing it. It can even be used to recycle old metal.
History
The earliest known example of metal casting dates back to around 3,200 BC in Mesopotamia. Today, it is just one part of the sheet metal fabrication available from experts such as those at dkmsheetmetal.co.uk. Modern cast metal parts are developed with computer-aided design and automation. It is an area of constant innovation.
Process
Casting generally begins with a pattern for the exterior. A core is produced for the hollow space. Moulding forms the cast around the pattern before the pattern is removed. Then the metal can be melted, poured, set, removed and given a final clean.
Methods
Sand casting: uses sand, clay and water for moulds. It is cost-effective for large, low-precision parts, but is often rough-surfaced. Shell moulding produces smoother surfaces, but is costlier.
Die casting: takes place in a steel mould and can be automated to create large numbers of small or medium-sized items, but is costlier and does not work with all metals.
Investment/lost wax casting: a wax pattern is covered with a ceramic shell, then melted. It produces intricate pieces such as jewellery, but is slow and labour-intensive. Plaster instead of ceramic is cheaper but more fragile.
Centrifugal casting: spins the mould, ensuring hollow or cylindrical parts are uniform.
It is important to understand all these different ways metals can be cast. They can produce a wide range of parts for various purposes.
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