Q: What is the definition of casting?

A: In the metal casting industry, there are two distinct meanings:

Casting refers to the process of creating a metal part (using cast iron or cast steel)
by pouring liquid into a mold or die to form a solid shape. Once the part cools and
solidifies, it is ejected or broken out of the mold.
There are several casting techniques used that offer varying degrees of quality,
precision, and economics. The three most common in the industry are sand
casting, die casting, and investment casting.
Casting terms can be used reciprocally. After the metal casting process is
completed, the finished object is universally referred to as a "casting".
Q: What is a metal casting?
A: Any metal casting process begins with an actual design of the part desired. A cast
steel foundry uses these designs and specifications to create a 3D dimensional
model that will represent the molds pattern or die. The pattern is the actual
shape of the object to be cast inside the molds cavity. As liquid metal enters the
cavity, it fills the pattern shape or void inside the mold to form the final casting.
After a period of cooling and solidification, the solid metal casting is removed from
the mold.

There are variations to the metal casting depending on the type of casting process
used.

Q: What kind of metal is used in castings?

A: Any metal that can be melted can be cast. Cast steel foundries can
accommodate different combinations of alloys and metals depending on the desired
objects structural and performance qualities. Throughout the industry, iron and
steel represent the most common metals used today. In order to categorize metals,
they are often referred to as Ferrous Metals and Nonferrous Metals.

Ferrous Metals: Metals which contain iron.

Examples of Ferrous Metals

Cast Iron, Gray Iron, Ductile Iron, Malleable Iron, Cast Steel (ASTM A27 Cast Steel is
a commonly used cast steel), Compacted Graphite Iron, Stainless Steel, &
Manganese Steel.
Nonferrous Metals: Metals which do not contain iron.

Example of Nonferrous Metals

Aluminum, Copper Alloy, Brass, Bronze, Zinc, Magnesium, Carbon & Low Alloy
Titanium, Corrosion Resistant Nickel, Heat Resistant Cobalt, Manganese and Tin.
A row of molds for cast iron
Q: What are common uses for castings?
A: Throughout the globe, metal casting represents a major sector for more than
90% of all manufactured goods and capital equipment. Whether it is for heavy
machinery or consumer goods, metal casting is used for a variety of applications.
Engineered components in capital equipment require castings. Farm equipment,
railroads, ships, oil and gas extraction, water processing, and mining cannot operate
effectively without precision metal casted parts. All sectors of the U.S. military use
castings for tanks, trucks, jet engines, and other vital defense related components.

In the consumer industry, items that we rely on everyday exist because of cast steel
foundries. Cars, trucks, air conditioners, refrigerators, lawn mowers, weight lifting,
and many moreutilize cast parts to maintain their operations. Even the very
production lines that create consumer products likely require casted parts.

Q: What do metal castings cost?

A: A casting cannot be created without knowing the specifications of the part
required. Considerable planning must go into the economics of casting. Depending
on the application for which the casting will be used, a number of questions are first
considered:

What is the application for the casted part?

What are the dimensions of the part to be cast?

What are the metallurgical requirements for the casted product?

Are their mechanical stress or thermal factors required for the casted product?

How many metal castings are required?

What type of finishing work is required after the cast is complete?

A seasoned team of veterans at Reliance Foundry will walk you through the entire
quotation and production cycle. Reliance Foundrys historical lineage spans nearly a
century. In that time, our team has forged a dependable method for planning, cost
savings, material selection, and quality control.

Two workers pour molten metal into a mold at Reliance Foundry, circa 1980s.
Q: How are castings made?
A: Since there are several commonly used casting processes, each will offer an
advantage depending on the requirements:

Sand Casting: Sand casting is considered the most common and can accommodate
a wide range of object sizes. The three dimensional replica or pattern of the
required object is held within a mold surrounded by compressed sand and binder
additives which are used to form the final shape of the desired part. After the
impression of the pattern is formed, the pattern is removed from the mold. Metal is
poured into the runner system of the molds cavity. Once solidified, the sand and
metal are separated, and the feeding system (ingates, runners and risers) are
parted from the raw casting. The casting is then cleaned, heat treated (as or if
necessary) and finished prior to shipping. The sand is often reused with some postproduction cleaning, screening and/or re-mixing with new additives; this sand is
quite often recycled when it is no longer usable within the foundry sand system.

Casting designs may also require hollow internal features or holes. In this case, a
core is placed inside the mold cavity to replace the volume of that hole and prevent
metal from entering. Once solidified, the mold is broken and the core is removed
from the part prior to finishing operations.
Die Casting: For complex engineered shapes which require dimensional accuracy
and precision, die casting is the most common approach. The molds are referred to
as dies. The dies are precision machined steel molds capable of withstanding high
pressure and temperature. Typically, die castings are made from nonferrous metals
although water-cooled ferrous metal dies are possible. Forcing molten metal into a
steel die results in several advantages. It allows for finer surface quality, higher
dimensional accuracy, and improved part detail. Die casting is especially
advantageous for small or medium sized parts requiring mold reusability and
consistency.
Investment Casting: Otherwise known as lost wax process, investment casting has
existed for at least 5000 years. In ancient times, beeswax was used to form
patterns. Still used by cast steel foundries worldwide, investment castings often
eliminate the need for machining a steel casting. The actual mold is created by
making an impression pattern with wax. The process typically uses wax; although
foam can also be used. The wax pattern is placed in a ceramic slurry which coats
the pattern and forms a skin that surrounds its surface area. The pattern is then
heated so the wax melts away leaving a cavity that can be filled with metal for final
casting.
Investment casting offers several benefits. This casting method produces objects
with intricately smooth surface contours and which may not require extensive
finishing.
Q: What are green sand castings?
A: Similar to sand casting, green sand casting utilizes a high degree of moisture in
the molding sand itself. The mold itself is not baked or dried. The mold material
consists of silica or olivine sand, bentonite (clay) to act as a bonding agent, and
water. Additional clays, chemical binders, refractory coatings and other oils are
often used to formulate the proper mold design, surface finish, and degasification
during the casting process. The primary difference in using sand casting and green
sand casting involves the actual weight limit of the part being cast. Green sand
casting offers virtually no weight limit while dry sand casting does have a mass
limit for parts.

Q: What are the differences between wrought iron vs. cast iron?

A: The primary difference between wrought iron vs. cast iron involves the process in
which the desired shape was achieved. Wrought iron is standard/stock metal that
has been heated and then worked with tools to produce its shape and form. Cast
iron is melted and poured into a mold to give it the desired look, shape, and surface
qualities (casting).

The next difference involves the purity of the metal which affects the overall
strength and workability of the product. Cast irons strength is affected by the
addition and removal of chemical agents which effect its purity. The more impurities
removed from cast iron, the easier it is to work with and result in a stronger or more
durable end product.

In terms of its properties, cast iron as not as pure as wrought iron but, with molds, it
can be used to create more accurate parts. In the early nineteenth century, wrought
iron work was an individual craft or trade but during the industrial revolution, the
development of more efficient casting processes made it less expensive to mass
produce metal goods.

A subset of cast iron, known as "ductile cast iron" was invented in the 1940s. It is
less brittle than cast iron and offered a higher degree of manipulation in terms of
flexibility and elasticity than traditional cast iron. Reliance Foundrys extensive line
of bollards include ductile cast iron products for use in historical restoration, traffic
safety, and architectural settings.

Q: What is the difference between a foundry and casting?

A: A foundry is a place where metal castings are produced. A casting is the process
of pouring liquid metal into the hollow cavity of a mold to form a desired shape
upon solidification.