The Advantages of Metal Casting

Published: 22nd November 2008
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Major industries in the United States are using metals for motor vehicles, oil field machinery, and power generation, among others. The discovery of metal casting or forming has paved the way to the success of many industries especially the automotive and mechanical. In fact, the surging development of the metal casting industry has saved about 15-20 tons of scrap metal from disposal in landfills and junkyards each year.

The process of metal casting involves the melting of metals at a high temperature before forming them in shapes. Manufacturing industries in highly developed countries mostly do this. Metal casting is a complex process which requires the proper equipment, knowledge, and degree of creativity.

Metal casting has several forms, the most popular is sand casting. It is a technique that has been used for many centuries now. Sand casting metal is the process of creating a specific shape out of a sand mixture by pouring the casting liquid into the mold of your desired shape. This type of casting allows manufacturers to create a large number of products that only require a small range of production expenses. Most metals are cast depending on the type of sand used in the molding process.

Die casting is another method if metal casting. It is the process of forcing molten metal under high pressure into mold cavities similar to permanent mold casting. It best suits the purpose of making small to medium sized parts fashioned with good and precise details. By-products of this method are coated with fine exterior finish and dimensional accurateness. Most materials used in this method are metals such as zinc, copper, and aluminum based alloys.

An additional process is the injection molding. It is a manufacturing technique in making parts from both thermoplastic and thermosetting plastic materials. It includes plastic injection molding wherein molten plastic is injected at high pressure into a mold, which is opposite of the product's actual shape. Example by-products of this method are bottle caps and outdoor furniture.

To further on techniques, there's the cold forming. It is also known as cold forging. Cold forming is a manufacturing procedure in which a metal is shaped at an ambient temperature to produce metal components in a definite shape. This procedure involves bending, cold drawing, cold heading, coining extrusion, thread rolling, and others.

Some benefits of cold forming are enhancements in the component properties of the product because the grain structure of the material is being elongated during the formation process, thus forcing it to follow the structure and strengthening it. Another advantage of cold forming is the aesthetic finish which has components that contribute to a brighter facade and its higher tolerance. These factors reduce the necessity of complex finishing and polishing.

These are only some of the many kinds of metal casting. Each type of technique produces products of high quality that would answer manufacturing or industrial needs.

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