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Metal castingis an indispensable and important link in the development of the equipment manufacturing industry. It is a commonly used manufacturing method with low manufacturing cost and high process flexibility. It can obtain complex shapes and large-scale castings, and it occupies a large proportion in machinery manufacturing. So in which industries does metal casting play an important role? Today, the Longsheng team will take you to find out. Let’s get started!

What is Metal Casting？

Metal casting is a manufacturing processthat involves pouring molten metal into molds to create 3D metal parts. The mold contains cavities of the desired geometry, and the molten metal cools to form the solidified part.
The word "cast" also refers to parts made through a casting process, which dates back 6,000 years. Historically, casting processes have been used to create complex and large parts that would be difficult or costly to create using other manufacturing processes.

Casting is the first choice for complex geometriesbecause it is more cost-effective and the process is simpler compared to, for example,CNC machining.But casting is also widely used for the simplest shapes because of its fast turnaround time and large production capabilities. Today, the use of cast products is so widespread that no matter what environment you are in, you cannot avoid using cast products. Some examples of cast metal products include engine blocks, fire hydrants, electric motors, tools, traffic lights, manholes, pipes, valves, and various fittings.

 

What Are the Key Applications of Metal Casting?

As an important manufacturing process,metal casting is widely used in many industries.The following are the main applications of metal casting in different fields:

1. Automobile industry

In the automotive industry, metal castings play an indispensable key role. The automotive industry has put forward higher quality and performance requirements for materials. Therefore, metal castings are increasingly used. For example, key components like engine blocks, brake discs and gears are often manufactured using metal casting techniques. In addition, automobile parts are also a special type of structural parts. Parts such as gearbox housings, steering columns, and bumpers all have complex shapes. Not only do these components need to have a high degree of strength and wear resistance, they must also have excellent heat dissipation capabilities and precise dimensional control. Traditional methods cannot guarantee the above characteristics, so advanced metal casting processes must be used to achieve the above goals. Through metal casting technology, we can meet these standards to ensure high quality and outstanding performance of automotive parts.

2. Aerospace and defense

In the aerospace and defense fields, metal casting technology is used to manufacture components with complex geometric shapes, such as aircraft engine components, missile components, etc. These components include compressor rotors, turbine blades, rocket engine nozzles, combustion chambers, high-pressure vessels, etc. These components must be able to withstand extremely high temperatures and pressures while also requiring extreme precision and reliability. Due to the large number of pores, shrinkage cavities and cracks inside metal castings, their mechanical properties are very different from conventional metal materials, thus becoming one of the main obstacles to manufacturing high-performance structural materials. Metal casting technology has the ability to produce high-quality and high-precision castings that meet the aerospace and defense industry’s stringent standards for material properties, weight management and safety.

3. Construction industry

In the construction field, metal casting methods are widely used in the manufacture of cast components such as pipe fittings, valves and building brackets. These include cast iron parts, cast iron pipes, steel castings, and other types of metal castings. Not only did the castings need to have sufficient mechanical strength and long-term durability, they also had to have excellent corrosion resistance and sealing properties. In order to ensure the above requirements, the metal casting process must be improved and optimized. Metal casting technology has the capability to produce castings that meet these standards, ensuring that construction equipment can operate safely and reliably.

4. Medical and health care applications

In the medical and healthcare sectors, metal casting technology is used to produce customized metal castingssuch as orthopedic implants. These implants need to be tightly integrated with the patient's bones and tissues and require good biocompatibility and corrosion resistance. Metal casting technology can provide high-precision, high-quality castings that meet the material performance and safety requirements of the medical and healthcare fields.

5. Electronic products and consumer goods

In the electronics and consumer products industries,metal casting techniques are used to produce thermally conductiveand heat-resistant housings and components. As consumers' requirements for product performance and appearance continue to increase, metal casting technology can provide products with excellent heat dissipation performance, beautiful appearance and durability. For example, casings and heat sinks in electronic products such as smartphones and tablets are often produced using metal casting technology.

6. Artworks and Sculptures

Metal casting also has its place in artistic creation. Artists use this technology to transform designed sculpture prototypes into bronze, brass and other metal works of art through processes such as the lost wax method. These works not only have high artistic value, but can also be preserved for a long time and become important carriers of cultural inheritance. In addition, metal casting is also used in the production of medals and commemorative coins. Through fine casting techniques, these items are given unique texture and historical significance.

What are the advantages and disadvantages of metal casting?

As a metal forming process with a long history,metal casting plays a vital role in modern manufacturing. It is not only capable of producing metal parts with complex shapes and precise dimensions, but also has high material utilization and cost-effectiveness. However,metal casting also has some inherent challenges and limitations.

Advantages of metal casting

1. Metal casting processes can manufacture workpieces with complex shapes especially complicated internal cavities, such as boxes, cylinder blocks, etc.;
2. Wide range of adaptations;
3. Themetal casting process can utilize low-cost ironand steel scrap, milling debris, etc., and casting equipment is relatively low.
4. The size and weight are almost unrestricted with metal casting workpieces;
5. The shape and size of the castings are very close to the workpiece. Therefore the metal casting process reduces the amount of further machining work and saves the metal materials.

Disadvantages of Metal Casting

1. The relatively more involved production operations make casting processes more challenging to be fully controlled;
2. The casting workpieces are more prone to take with casting defects;
3. Relatively poor dimensional consistency and accuracy;
4. Compared with forgings of the same size and shape, the intrinsic quality of castings is weaker, and the load-bearing capacity is less than that of forgings;
5. Poor working environment with high temperature, dust, and high labor intensity.

Comparison of Different Casting Techniques for Various Applications

Different casting technologies have their own unique features in product applications. The following is a comparison of sand casting and die casting, investment casting and centrifugal casting:

1.Sand Casting

Sand casting is a universal casting process that can be used to cast any metal alloy, whether ferrous or non-ferrous. It is widely used in mass production in industrial units such as automotive metal casting parts such as engine blocks, cylinder heads, crankshafts, etc.

The process uses molds made of silicon-based materials, such as naturally bonded sand or synthetic sand, to create a smooth mold surface. The mold surface has two parts, the upper mold (upper part) and the lower mold (lower part). A pouring cup is used to pour molten metal into the mold, where it solidifies to form the final shape. Finally, excess metal is trimmed off to complete the final metal cast product.

2.The Casting

While sand casting can melt alloys with higher melting points, you can use die casting to shape metals with lower melting points. After changing the material from a solid to a hot molten liquid, you can inject it into a long-life die-cast mold made of hardened steel. These tools consist of a cavity, a core, and sometimes an insert. Unlike plastic injection molding, machining side features after casting is sometimes more feasible than using side actions. Die casting dates back to the 19th century.

Since its emergence in the manufacturing world, two types of programs have been developed for your use. The first is a hot chamber, which features a built-in furnace within the machine to melt the material. If you use the cold chamber process, the second procedure, you melt the material in a separate furnace and then move the molten material into the injection chamber. You can implement die casting for high-volume production of aerospace and automotive parts, as well as toys, furniture, and electronics. Die casting is provided through Longsheng's core services, and quotes can be created through the instant quote engine.

3.Sand Casting vs. Die Casting

1.Startup Time

Firstly, the startup time for these processes can be vastly different. Sand molds can be made very rapidly if the desired pattern is already at hand. Making a steel die for die casting, however, takes longer since it needs to be designed, machined, tested, and affixed to the equipment, which can be very time-consuming.

The setup and required machinery for die casting also mean much larger upfront costs than sand casting. The investment in die casting equipment generally only makes sense for higher production volumes.

2.Surface Finish

Another difference between sand casting and die casting is the surface finish of castings made from these methods. Sand casting leaves behind rough surfaces on parts because the compacted sand imprints its texture onto the cast. Specialized sands and other measures can reduce roughness, but this comes with extra cost. Die cast products, however, boast a very high-quality surface finish due to both the smoothness of the die’s inner walls and the pressure used to fill the die. Note that designed textures can also be added to die cast parts if desired.

3.Complexity of Parts

While both methods can create complex part shapes, die casting is often the preferred process for these types of casts. Thanks to pressure injection of the molten aluminum, die casting can make components with very thin walls. The pressure injection also leads to greater dimensional accuracy for cast parts relative to sand casting.

 

1.Investment Casting

Investment casting, also known as lost wax casting, uses a disposable wax pattern coated with ceramic material that solidifies into the shape of the casting. The first step in this casting process is to create a wax pattern, usually made of wax or plastic. Because the process requires precise measurements, multiple trials and errors make investment casting an expensive manufacturing process. The wax is poured into the mold, carefully removed, and then coated with adhesive or refractory material to form a thick shell. Additionally, multiple models are assembled onto the main gate. Once the shell has hardened, the model is turned over and heated in the oven to remove the wax. The molten metal is poured into the remaining shell and solidifies into the shape of the wax mold. Additionally, the refractory shell is broken off to reveal the finished casting. This casting process is commonly used to make power generation, automotive and aerospace components.

2.Centrifugal Casting

Centrifugal casting, also known as spin casting, is a process that uses centrifugal force to manufacture cylindrical parts industrially. This type of metal casting uses a preheated rotating mold into which molten metal is poured. Centrifugal force helps disperse the molten metal within the mold at high pressure.
There are three types of centrifugal casting: true centrifugal casting process, semi-centrifugal casting process and vertical centrifugal casting process. Semi-centrifugal casting differs from true centrifugal casting in that it uses a gate to completely fill the mold. However, in true centrifugal casting, the molten metal sticks to the sides due to the continuous rotation. In contrast, vertical centrifugal casting, as the name suggests, uses directional molding, following the same process as true centrifugal casting.
Typically, centrifugal casting produces a rotating shape that resembles a cylinder. Especially parts such as bearings, clutch plates, piston rings and cylinder liners. Additionally, pouring metal in the center of the mold helps reduce defects such as porosity, shrinkage, and air pockets. However, it does not work with all types of metal alloys.

Investment Casting vs. Centrifugal Casting

Feature	Investment Casting	Centrifugal Casting
Process & Precision	Known for precision, suitable for complex shapes with intricate details. Involves creating a wax model and a ceramic mold, allowing high accuracy.	Suited for cylindrical parts, uses rotational force for uniformity. Less versatile in shape complexity.
Material & Quality	Versatile with materials, suitable for various alloys. Ideal for parts enduring extreme conditions like high temperatures.	Produces parts with high material integrity, drives impurities out, resulting in dense, high-quality metal.
Applications	Used in aerospace, automotive, medical equipment for complex, precision parts like turbine blades, gearboxes, surgical tools.	Common in producing large cylindrical components like pipes, bearings, and bushings, used in automotive, marine, machinery sectors.
Cost & Efficiency	Can be costly and time-consuming due to intricate process, but cost-effective for small runs or precision-required parts.	Faster and more cost-effective for large-scale production of cylindrical parts, more material-efficient.
Flexibility & Limitations	Offers flexibility in part design but requires more steps, adding complexity and production time.	Limited to symmetrical shapes but provides a straightforward process, efficient for producing large parts.

What Materials and Molds Are Used in Metal Casting?

It all depends on the type of casting you're doing, but these are the most common materials you'll use when using these casting methods:

• Metals: Certain casting methods can be adapted to the metal you want to melt, such as iron, aluminum, copper, and zinc.
• Alloys: A variety of alloys, such as bronze and brass, can be melted and cast whether using sand casting or metal molds.​
• Ceramics: These materials are commonly used in pottery applications and include clay or porcelain.​
• Plastics: These bendable materials can also be shaped by casting.
• Composites: Resin and fiber blends and other composite materials are another suitable option that you can use in your casting process.
• Rubber: For parts that are elastic and flexible, rubber can be used in casting.​
• Glass: If you need art or thin-walled items, glass can be incorporated into certain casting processes.
• Concrete: This is a common choice when manufacturing building products and decorative castings.

FAQs

1.What are the main applications of metal casting in industry?

Metal casting has a wide range of applications in industry. For example, metal casting can be used in machinery manufacturing to produce mechanical parts of various shapes and sizes, such as gears, bearings, boxes, etc. Casting occupies an important position in the automotive industry and is used to produce key components such as engine blocks, cylinder heads, crankshafts, and transmissions. In the aerospace field, casting technology is used to produce high-performance, high-precision parts such as engine blades, turbines, and casings. Casting is used in shipbuilding to produce hull structural parts, engine components, etc. to ensure the strength and durability of the ship. Casting is used in the power industry to produce key components such as generator stators, rotors, and transformer cores.

2.What types of metal are typically cast?

Commonly used types of metals used in the casting process include: Cast Iron: Cast iron is one of the most commonly used materials in casting. It has good casting properties and mechanical properties and can be used to produce a variety of structural and mechanical parts. Cast steel: Cast steel has high strength and toughness and is suitable for producing parts that can withstand heavy loads and impacts, such as bridges, building components, etc. Nonferrous metal alloys: including aluminum alloys, copper alloys, magnesium alloys, etc. These alloys have excellent casting properties and physical properties and can be used to produce various precision parts and thin-walled parts.

3.How does sand casting differ from other casting methods?

Compared with other casting methods, sand casting has the following differences: Mold material: Sand casting uses sand as the mold material, while other casting methods such as metal mold casting, investment casting, etc. use materials such as metal or ceramics as the mold. Process characteristics: The sand casting process is flexible and suitable for producing parts of various shapes and sizes; other casting methods may be limited by the shape and size of the mold. Cost: Sand casting costs are relatively low because sand is readily available and reusable as a mold material; other casting methods may require higher mold costs. Scope of application: Sand casting is suitable for producing larger batches of parts, while other casting methods may be more suitable for producing high-precision, small-volume parts.

4.What are the advantages of using casting in manufacturing?

The main advantages of metal casting are that it can manufacture workpieces with complex shapes, especially complex inner cavities, such as boxes, cylinders, etc.; It has a wide range of adaptability; the metal casting process can utilize low-cost steel scraps, milling scraps, etc., and the casting equipment is relatively low. There are almost no restrictions on the size and weight of metal casting workpieces; the shape and dimensions of the castings closely match the workpieces. Therefore, the metal casting process reduces the workload of further machining and saves metal materials.

Summary

Metal casting plays a vital role in the automotive industry, aerospace and defense, construction, medical and healthcare applications, electronics and consumer products, art and sculpture. In short, as an ancient and constantly innovative process, metal casting not only occupies a pivotal position in modern manufacturing, but also plays an irreplaceable role in promoting scientific and technological progress and promoting industrial upgrading. With the development of materials science, computer simulation technology and automation technology, metal casting technology is moving towards higher precision, higher efficiency and more environmental protection.

Disclaimer

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Longsheng Team

This article was written by multiple Longsheng contributors. Longsheng is a leading resource in the manufacturing sector, withCNC machining,sheet metal fabrication,3D printing,injection molding,metal stamping, and more.