Casting and Casting Processes

Abstract

The casting process was discovered probably around 3500 BC in Mesopotamia. Casting is unique manufacturing processes for a variety of reasons. Perhaps the most obvious is the array of molding and casting processes available that are capable of producing complex components in any metal, ranging in weight from less than an ounce to single parts weighing several hundred tons. Foundry processes are available and in use that are economically viable for producing a single prototype part, while others achieve their economies in creating millions of the same part. Virtually any metal that can be melted can and is being cast. Many parts and components are made by casting, including automotive components such as carburettors, engine blocks, crankshafts, agricultural and rail road equipments, pipe and pumping fixtures, power tools, gun barrels and large components of hydraulic turbines etc. Since 1950, partially automated casting processes have been developed for production lines.It is estimated that castings are used in 90% or more of all manufactured goods and in all capital goods machinery used in manufacturing. The diversity in the end use of metal castings is a direct result of the many functional advantages and economic benefits that castings offer compared to other metal forming methods. The beneficial characteristics of a cast component are directly attributable to the inherent versatility of the casting process.