Casting

Not all metals are amenable to the mechanical deformation which occurs with mechanical forming processes discussed in the previous sections. Those metals that can undergo mechanical forming are referred to as wrought metals. For those metals that are not amenable to mechanical deformation, they are typically cast.

Casting is the process in which molten metal is poured (or cast) into molds. In the reading, you were introduced to five different casting techniques: sand, die, investment, lost foam, and continuous. Typically, it is more economical to use mechanical forming processes, since it requires more energy to heat metals until molten in the casting process. However, there are times when casting makes more sense, in addition to the obvious case of a metal not being amenable to mechanical deformation. Some of those cases include when making complicated shapes or when prototyping a part. When prototyping, the cost of making a forging die might be much more expensive than the cost of molds.

To Watch (2:54 minutes) (This video has no narration, text below)

What is A Foundry?

[MUSIC]

[TEXT ON SCREEN] What is a Foundry? Foundries are factories where castings are produced by melting metal, pouring the liquid metal into a mold, then allowing it to cool and solidify. The casting process includes pattern making, molding, melting, pouring, ejecting from mold, cleaning, fettling, and inspection. Foundries also house a number of operations that often include part design, tool building, prototyping, machining, assembly, and other after-sales services. Modern foundries are heavily mechanized. They contain all the machinery and equipment used in pattern and core making, casting, and molding. That assortment includes large melting furnaces, ladles, forklifts, cranes, conveyors, and transfer vessels. The fundamental distinction between foundries is ferrous (iron or steel) and non-ferrous (aluminum, brass, bronze, copper, etc.). Charging-loading metal into the furnace for melting-is one of the most dangerous operations in the foundry. A small mistake can cause anything from destruction of equipment to an injury or fatality. Safety conscious design and protective gear help mitigate the risk to workers and equipment, but the true key to safe foundry operations is skilled foundry workers with excellent situational awareness, strength, and endurance. There is a growing demand for completely finished and ready to install parts. Foundries are evolving to offer more cleaning and machining capabilities. To learn more about foundries, please visit RelianceFoundry.com. 

Credit: Reliance Foundry. "What is A Foundry?" YouTube. December 10, 2021.

Now, please go to the second reading (2 of 3) of this lesson and read about how ceramics are fabricated.