Benefits Of Iron Casting As A Manufacturing Process - Calmet

Benefits Of Iron Casting As A Manufacturing Process

The process of casting involves converting a molten metal into a pre-engineered form or shape and is the most preferred method of metal forming process, simply because it features numerous inherent advantages that enable the formation of intricate and integral streamlined parts, which cannot be obtained by any other comparable methods. Moreover, the developments in the field of science and technology have made it possible to cast parts that are practically impossible to be made by any other method such as forging, welding or stamping. Some of the prominent benefits of using casting as a manufacturing process are highlighted below.

The biggest benefit that drives manufacturers to use casting is that it offers tremendous design flexibility. Any object that ranges from 5gm to 200 tons of any shape or size can be easily cast. It is a very flexible methodology that allows the use of complex design techniques, which cannot be employed in other production methods. Also, it enables rapid transition to finished product as it involves a very simple and uncomplicated manufacturing process. The molten metal is poured into a cavity that measures similar to the dimensions of the final product. Casting is without doubt the simplest and most popular method of forming metal. Moreover, the physical properties of certain metals require only casting process, as it is not possible to re-model it into rods, bars or plates. Casting offers the best design flexibility when compared to other production methods such as forging, welding, rolling or stamping.

Casting also offers a significant advantage in the form of enabling the formation of attractive designs, as there is no restriction to the assembly of pieces or shapes. There are several types of casting processes that can be used to obtain the type of finish needed from casting. Sand molding provides a rugged appearance and other methods such as shell molding and investment casting provide for a smoother surface. Casting also contributes to minimizing the residual stress in the finished product that comes from casting.

Casting is perhaps the most reliable and durable method of metal casting as it utilizes good design principles and conducts periodical examination of mechanical properties to test the bars that are cast from the molten metal. This ensures the high dependability and reusability of the metal, which is typically not possible when using other methods. Also, the highly dependable method enables designers to combine several parts into a single fabrication, which reduces the possibility of future leakages. This also contributes to casting being a reliable method of metal forming.

Cost saving is perhaps the most significant benefits that arises due to use of casting process. Since casting enables combining a number of parts into one single fabrication, it drastically reduces costs associated with fabrication. Also, it requires a shorter lead-time for production, which also results in lower costs incurred. Moreover, the design flexibility and freedom contributes to minimizing costs related to machining and excess metal.

Most iron casting manufacturers combine casting along with another process which tends to be more efficient or better suited for the requirements of a particular project.