Casting is a manufacturing process used to
create solid metal objects by pouring molten
What is Casting?
metal into a mold cavity, where it solidifies and
takes on the shape of the mold
1 Complex Geometries
2 Material Flexibility
Why Casting? 3 Cost-Effectiveness
4 Scalability
5 Material Utilization
Engine Blocks
Cylinder Heads
1 Automotive Industry
Transmission Cases
Suspension Components
Introduction to Casting
Engine Components
2 Aerospace Industry
Turbine Blades
Structural Components
Aerospace alloys
Gears
3 Heavy Machinery and Equipment
Housings
Frames
Where it's Used?
Hydraulic Components
Turbine Components
4 Energy Sector
Generator Casings
Wind Turbines
Plumbing Fixtures
5 Consumer Goods
Decorative hardware
Jewellary
Introduction to
Casting Design
6 Medical Equipment
Surgical Equipments
Where High Mechanical Properties Required
Steel excellent strength, durability, and versatility
( Automotive & Machinery Components )
Where weight reduction is crucial, such as
Aluminium lightweight yet strong characteristics
aerospace, automotive, and consumer goods.
Gray Iron good machinability and damping capacity engine blocks and brake components
applications requiring impact resistance, such
Iron Ductile Iron high strength and ductility
as gears and shafts.
applications requiring moderate strength and
Malleable Iron Heat Treated Cast Iron improved ductility and toughness ductility, such as pipe fittings, agricultural
equipment, and ornamental castings.
excellent thermal and electrical conductivity, electrical components, plumbing fixtures, and
Materials Used for Casting Copper and Copper Alloys
corrosion resistance, and aesthetic appeal decorative hardware
lightweight casting applications in automotive,
Magnesium excellent strength-to-weight ratio
aerospace, and consumer electronics industries
high strength, corrosion resistance, and aerospace engine components, medical
Titanium
biocompatibility implants, and marine equipment.
consumer and industrial products, including
low melting point, excellent fluidity, and
Zinc commonly used in die casting applications automotive parts, hardware, and electronic
dimensional stability.
enclosures
used in components subjected to extreme
offer superior strength, corrosion resistance,
Nickel Alloys environments, such as turbine blades, valves,
and high-temperature performance
and pumps.
1 Sand Casting
Investment casting is a precision casting
process that involves creating a wax pattern of
2 Investment Casting the desired part, coating it with a ceramic slurry
to form a shell, and then melting out the wax to
leave behind a hollow ceramic mold.
Types of Casting Processes 3 Die Casting
ses reusable metal molds instead of disposable
4 Permanent mold casting
molds
5 Centrifugal casting
1 Material Selection
2 Part Geometry and Complexity
3 Draft Angles and Fillets
4 Wall Thickness Uniformity
5 Ribs and Bosses
Basic Design Considerations
6 Undercuts and Parting Lines
7 Gating and Riser Design
8 Machining Allowances
9 Surface Finish Requirements
10 Assembly Considerations
Basic Design Process
Define Requirements
Conceptual Design
Material Selection
Detailed Design
Draft Analysis and Optimization
Gating and Riser Design
Simulation and Analysis
Prototype Development
Documentation and Drawing Creation
Manufacturability Review
Finalization and Approval
Continuous Improvement
Engine Casing & Cylinder Head
Heavy Machines Housings & Hydraulic
Trending Subdomains Components
Aerospace Engine Components
