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Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. [1] Casting processes have been known for thousands of years, and have been widely used for sculpture (especially in bronze), jewelry in precious metals, and weapons and tools.
A bronze casting showing the sprue and risers. A riser, also known as a feeder, [1] is a reservoir built into a metal casting mold to prevent cavities due to shrinkage.Most metals are less dense as a liquid than as a solid so castings shrink upon cooling, which can leave a void at the last point to solidify.
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.
Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries ...
Bronze casting showing sprue and risers. A sprue is a large diameter vertical channel through which liquid material is introduced into a mold. It connects the pouring basin to the runner. In many cases it controls the flow of material into the mold.
Bronze is widely used for casting bronze sculptures. Common bronze alloys have the unusual and desirable property of expanding slightly just before they set, thus filling the finest details of a mould. Then, as the bronze cools, it shrinks a little, making it easier to separate from the mould. [30]
Gunmetal ingot is a related alloy in which the zinc is replaced by 2% lead; this makes the alloy easier to cast but it has less strength. [2]Modified gunmetal contains lead in addition to the zinc; it is typically composed of 86% copper, 9.5% tin, 2.5% lead, and 2% zinc.
Permanent mold casting. Permanent mold casting is a metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold, however gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces