The Casting Process


Casting is a process used to produce metal parts by pouring molten metal into a mold. Depending on the type of manufacturing and the number of pieces we want to produce, we choose one type of mold or another. In our tooling department, we specialize in the production of casting molds. With our molds made from iron alloys, it is possible to mass-produce aluminum and zamak parts. The casting process itself is simple: the molten metal is poured into the specialized mold and left to cool. To extract the desired metal piece, there are logically many more factors and variables that we must consider.

Casting: An Ancient Art

Casting is a technique that has been applied for many centuries. The first castings occurred in China in the 1st century BC. In America, before colonization, copper and silver casting was achieved in the 10th century. Castings did not reach Europe until the 13th century with the first blast furnaces.

Other Casting Methods Used Today

Casting methods have become more sophisticated as technological development has progressed, being replaced by:

Die casting: A method for manufacturing non-ferrous metal parts. The metal is injected under pressure into a steel mold.

Forging: A deformation process where metal is compressed between two dies using pressure to form the part.

Extrusion: First, there is compression where the metal is forced to flow through a die opening to shape it into another section.

Machining and rolling: A deformation process where the material’s thickness is reduced with compressive forces exerted by opposing rollers.

What is Casting Like?

Before proceeding, a mold is needed. The cavity in the mold must be perfectly designed in shape and size to allow proper solidification. Each metal undergoes a percentage of contraction, so each mold must be prepared and the casting processes adjusted accordingly.

The metal is heated to the appropriate temperature for each mold. The molten metal is poured into the mold. In an open mold, the liquid metal is deposited inside the mold. When the molten material begins to cool to a sufficient temperature, solidification starts, involving a phase change of the metal. The metal takes the shape of the mold cavity. Then, the excess metal from the casting is trimmed, the surfaces are cleaned, and thermal treatment is applied.

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