Metalcasting is a manufacturing process in which metal is melted and poured into molds where it solidifies into geometrically complex components. Metalcasting is unique among metal component forming processes for a variety of reasons.
First, the array of available metalcasting processes are capable of producing very simple to extremely complex components in almost any metal, ranging in weight from less than an ounce to several hundred tons. In addition, metalcasting processes are available that make it economical to produce a single prototype part, while others achieve their economies in creating millions of units.
In terms of value and volume, metalcasting ranks second only to sheet steel, which begins by casting steel slabs, in the metal producing industry. According to U.S. Department of Commerce statistics, metalcasting remains one of the ten largest industries when rated on a value-added basis. Annually, more than 2,000 metalcasters produce 13 to 15 million tons of castings valued at $35 to 40 billion (according to 2008 statistics).
The key to metalcasting design and purchasing comes down to understanding the metal-process marriage.
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Census of Global Casting Production |
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Each year, MODERN CASTING surveys the world's casting-producing nations to compile the global production numbers of metal casting shipments.
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Raw Materials Trends in 2011 |
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MODERN CASTING examined raw material trends in 2011 in a three-part series.
Sand Shortage: Reality or Myth?: Reality or Myth? With foundry sand prices escalating and shortages reported by multiple suppliers, molding material has some purchasers biting their nails.
Melt Additives Supply Tightening Rare earth elements and several other materials are in short supply, with costs steadily rising. Could scarcity be next?
Alloy in Demand No raw material supply issue is felt more deeply in a metalcasting facility than a potential shortage of primary casting alloys.
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Diecast Zinc Alloys |
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While traditionally focused in automotive, hardware and plumbing markets, diecast zinc alloys have become an alternative material of choice in consumer product industries such as communications, electronics and home appliances.
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Magnesium Alloys |
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Cast magnesium alloys have gained popularity in recent years due to their ability to maintain high strengths at light weights. Magnesium possesses unique properties that can open the door to important markets for structural applications and has gained widespread use in automotive components. Further, non-automotive applications, spurred on by the computer, electronics and power tool industries, continue to expand.
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Copper-Base Alloys |
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Cast copper alloys are known for their versatility. They are used in a wide range of applications, such as plumbing fixtures, ship propellers, power plant water impellers and bushing and bearing sleeves, because they are easily cast, have a long history of successful use, are readily available from a multitude of sources, can achieve a range of physical and mechanical properties and are easily machined, brazed, soldered, polished or plated.
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Aluminum Alloys |
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Cast aluminum components are used for many functions, from decorative home-owner components, such as lighting fixtures, to highly engineered, safety-critical components for aerospace and automotive applications.
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Steel Alloys |
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Steel castings have a variety of end-use applications that require a heavy-duty component. These castings are used in parts for railroad cars, pumps and valves, heavy trucks, construction and mining equipment and power generation equipment. A good steel casting application can provide strength while utilizing a flexible geometry inherent with the metalcasting process.
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Iron Alloys |
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Iron castings are produced by a variety of molding methods and are available with a wide range of properties. Cast Iron is a generic term that designates a family of metals. The six types of cast iron are gray iron, ductile iron, compacted graphite iron (CGI), malleable iron, white iron and alloyed iron.
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Rapid Prototyping |
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Rapid Prototyping (RP) is a general name that encompasses numerous methods used to fabricate objects from CAD data. There are a number of different RP processes, and new developments are constantly being made.
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Ceramic and Plaster Mold |
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This family of casting processes is unique in that ceramic and plaster are used as molding media. These processes offer a high degree of precision in regard to dimensions, as well as excellent surface finishes.
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Permanent Mold Casting |
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At least three families of molding and casting processes can be categorized as permanent mold processes. These include diecasting (high-pressure diecasting), low-pressure permanent mold casting and permanent mold casting. Unlike sand casting processes, in which a mold is destroyed after pouring to remove the casting, permanent mold casting uses the mold repeatedly.
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Metalcasting Basics 