Casting

Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.

Metal casting history and development can be traced back to Southern Asia (China, India, Pakistan, etc).

[5] Since the beginning of metallurgy the majority of castings were simple one- to two-piece molds fashioned from either stone or ceramics.

The direct molding method requires craftsmen to have a high technical level; otherwise, the quality of castings cannot be guaranteed.

[8] Early civilizations discovered lead aided in the fluidity of molten copper, allowing them to cast more intricate designs.

Multiple molds were placed on top of one another into a clay cylinder so molten metal could be poured down the center, filling and solidifying in the open spaces.

[4] In the Middle East and West Africa, the lost wax technique was used very early in their metallurgy traditions, while China adopted it much later.

However, the discovery of a mask made using the investment moulding dated at around 1300 BC indicated that the lost wax technique may have influenced other regions in China.

Alternatively, the material is altered in its initial casting process and may contain colored sand so as to give an appearance of stone.

[11] The process of cutting, grinding, shaving or sanding away these unwanted bits is called "fettling" in British English.

This has benefits beyond a reduction in pre-production sampling, as the precise layout of the complete casting system also leads to energy, material, and tooling savings.

The software supports the user in component design, the determination of melting practice and casting methoding through to pattern and mold making, heat treatment, and finishing.

Since the late '80s, commercial programs (such as PoligonSoft, AutoCAST and Magma) are available which make it possible for foundries to gain new insight into what is happening inside the mold or die during the casting process.