Everything You Need to Know About the Iron Casting Process

Are you wondering if metal casting is the best fit for your needs?  Metal casting, or iron casting, is the process of using molten metal to shape it into a solidified part. The part can get formed by pouring molten metal into a molder where it’s cooled, taking the shape of the mold. It relies on recycling metals as a cost-efficient source of raw material.

Metal casting has been around for many centuries, often done by professional smiths. It became the earliest and most used process that has got passed down in history. Many people still use these techniques to make metal objects for daily life, like cutlery.

If you want to learn about the industry, then look no further. Here is our guide that you all need to know about metal casting.

Iron Casting Process – History of it

The oldest known product of metal casting is in the shape of a copper frog. Researchers believe it was first made in Mesopotamia during the BCEs. After the discovery of iron, the iron casting process got started around 700 BCE in China.

The first technique they use on metal casting is the crucible process. This iron casting process is hard to track as it keeps appearing and disappearing. However, it’s theorized that it popped out first in central Asia, which later went to Europe.

The technique didn’t resurface until it got reinvented once again in 1750. Benjamin Huntsman discovered it when he was heating steel in a closed crucible. The ceramic pot later then helped shape the steel into what he wanted.

Metal casting then started to evolve from manual labor to fully automated.

The automated work is now done by machine, which does a lot more than sheet metal fabrication. However, the entire iron casting process at its core remained the same.

Raw Materials Used

Making cast iron begins with a wide array of raw materials. You can use our iron which is rarely found in meteorites.

However, you can also use earth-based iron, having other elemental parts in the mix. This elemental combination is what we call iron oxides.

When mining iron, the ores get pulled out of the earth’s outer layer. The iron ore goes into a blast furnace to create pig iron.

Pig iron offers few industrial uses due to its brittle nature. Once it’s allowed to mix with other elements, it takes on a new form. From this, iron is then converted into various types of industry.

Producing Metal Cast

Metal or iron casting describes grey cast iron together with the other alloy. You can identify the product by its color and texture, but it undergoes several processes.

First is patternmaking, which replicates the exterior portion of the casting. The patterns can come from wood, metal, or plastic. This step is essential in industries for building and architecture.

The next step of the iron casting process is core making. It’s where the metal fabrication shapes the internal form to make it hollow. This step makes the core metal strong but still collapsible so it can be easy to remove.

Then we have the molding phase, where the metal will take shape. However, before the metal can even take shape, it needs to get poured into molten metal. It should not leave an open space in the cavity for the metal to form the wanted shape.

After all the procedures, you may now proceed to clean the cooled mold. Polish and shine the mold’s rough edges to make it look clean and presentable.

Industries That Rely on the Iron Casting Process

Metal casters produce different and complex metal shapes. They use a variety of materials for their components to serve different purposes. The purpose can vary from each industry, such as agriculture, healthcare, and mining.

In agriculture, metal castings are mostly used for machinery for production. They require well-designed parts for precise yield growth and storage. That’s why durability and productivity are essential to maintain quality products.

Casting will always be a vital part of vehicle production. They form metal castings that will become essential parts for the vehicle to be able to run. These parts are also the ones that keep us safe, wherever we’re at when driving.

On the other hand, metal casting in healthcare promotes health and safety. They rely on this material for medical tools and devices to treat patients every day. Without some of the materials, it could result in death.

Lastly, we see metal casting products used in the construction of buildings. We relied on steel as a building material for its sturdy foundation it provides the building. Without castings, it would be difficult for the structure to last long.

Modern Day Casting

Today, almost every device we use has metal parts that came from metal casting. The difference between from then to now is that the precision of making the cast is easier. It’s all thanks to automation.

Modern casting now follows different types of creation. Some products get cast in engines, needing high tolerance for heat and cold. Others get cast on iron pipes to resist corrosion.

Die casting requires two large metal parts. These non-ferrous metal parts clamp together under pressure. Molten steel is then injected into the cast, forming the mold.

Investment casting begins by filling the mold with wax. Once it hardens, it gets coated in a ceramic material. This allows the mold to melt.
Later molten metal gets poured and allowed to cool.

Metal Casting Resources For Your Business Today

Metal casting plays an essential role not only in the industry but in our daily lives. It helps us achieve our daily tasks with ease. Partake in this kind of business today and enjoy its benefits.

We hope this guide helped you learn metal casting. But it shouldn’t end here. There’s more to learn and we’ve got the tips and services to help.

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