Metal casting

Abstract

Casting is a cost-effective route to make extremely complex geometry near net shape components. To reach the full potential in the cost/complex performance, it is essential to understand the whole manufacturing route. This chapter on metal casting covers the fundamental of the metallurgical aspect of melting, and casting of both ferrous and nonferrous materials is covered. This includes furnaces and melting practices. The shaping of casting is described in more detail including mold filling and solidification. An overview of pressure die casting, die casting, and disposable mold casting including both sand and ceramic molds is covered. Important constraints such as process alloy capability and ability to produce complex and sound geometries are covered as well as the first basic steps towards a sound design are covered. In the description of the route to sound castings, Campbell’s Ten Commandments are followed and discussed in detail. Last but not least, the metal alloys and their microstructure and properties are treated covering both ferrous and nonferrous alloys.