6 Main Steps of Metal Casting Process Explained

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6 Main Steps of Metal Casting Process Explained

Metal casting is a metalworking procedure that involves liquid metal with a mold. The process is in use for hundreds of years and keeping history in mind, metal casting has been applied to diverse things. It includes manufacturing wind turbines to swords and today it is among the most versatile and valuable techniques for making top-quality metal parts and custom metal molds.

This blog post looks at the fundamentals of casting metal, which include its different variants such as investment casting, die casting, etc., and the renowned casting metals. 

The metal casting process explained

The central metal casting process involves

  • metal heating,
  • inserting it into a mold,
  • waiting for cooling and solidifying,
  • erasing the finished part from the mold

Realistically speaking, there may be many stages to the process while various metal casting processes operate in varying ways. The below-mentioned is a simplified review of a metal casting process.

1. Designing the pattern:

First thing first, different metal casting processes need the pattern fabrication and a final part’s duplicate that is used for making the mold. Patterns can be either expendable or permanent and can be manufactured from materials such as wood, wax, and plastic.

2. Designing the core:

For the hollow parts’ casting, it might be necessary to make a core, a robust piece of material inserted inside the mold cavity, which shapes the interior geometry of a cast part. (For instance, a cylindrical core inside the larger cylindrical mold that will produce a tube-shaped cast part).

3. Designing the mold:

Custom metal molds manufacturers make molds in different ways as per the process. For instance, a CNC machine can be made through permanent metal molds, while sand molds can be manufactured by applying a sand mixture to a pattern’s exterior. The process of fabricating molds is called mold making.

4. Filling the mold:

Now, metal will be heated up until it melts down and then poured into the mold. In gravity mold casting, the molten stuff is poured into the cavity downwards. In die casting (high pressure), it is forced into the cavity with high clamping forces needed for the security of the die.

5. Removing the part:

Once the die cast part is cooled and solidified, it is erased from the mold. For processes such as sand casting, the mold is destroyed to get to the inside part; for permanent molds, the two halves of the metal mold are separated to make it ready to use again.

6. Post-processing:

Before cast metal parts are ready for use, they may need to be cleaned — to remove mold remnants, for example — or undergo other post-processing steps.

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