Manufacturing Processes: Casting

Study Notes

Process of pouring molten metal into a mold to create a desired shape
Types of casting:
- Sand casting: uses sand as the mold material
- Investment casting: uses a wax pattern to create a mold
- Die casting: uses a metal mold to produce high-volume parts
Advantages:
- Can produce complex shapes
- Can be used with a wide range of metals
- Can produce parts with good surface finish
Limitations:
- May have porosity or other defects
- Can be expensive for small production runs

Process of shaping metal using localized compressive forces
Types of forging:
- Open die forging: uses a flat die to shape the metal
- Closed die forging: uses a die with a specific shape to produce a precise part
- Impression die forging: uses a die with a recessed area to produce a part with a specific shape
Advantages:
- Can produce parts with high strength and durability
- Can be used to produce parts with complex shapes
- Can be more cost-effective than casting for large production runs
Limitations:
- May require significant force and equipment
- Can be difficult to produce parts with precise dimensions

Process of shaping and forming metal sheets into desired shapes
Types of sheet forming:
- Bending: uses a die to bend the metal sheet into a specific shape
- Drawing: uses a die to shape the metal sheet into a cup or box shape
- Stretching: uses a die to stretch the metal sheet into a specific shape
Advantages:
- Can produce parts with high precision and accuracy
- Can be used to produce large quantities of parts
- Can be used with a wide range of metals
Limitations:
- May require significant force and equipment
- Can be difficult to produce parts with complex shapes

Process of joining two metal parts together using heat and pressure
Types of welding:
- Shielded Metal Arc Welding (SMAW): uses a consumable electrode to join the parts
- Gas Metal Arc Welding (GMAW): uses a continuous wire electrode to join the parts
- Gas Tungsten Arc Welding (GTAW): uses a non-consumable tungsten electrode to join the parts
Advantages:
- Can be used to join a wide range of metals
- Can be used to produce strong and durable joints
- Can be used in a variety of applications
Limitations:
- May require significant skill and training
- Can be difficult to produce high-quality joints
- Can be affected by heat and distortion

Casting is a process of pouring molten metal into a mold to create a desired shape
Types of casting: sand casting, investment casting, die casting
Advantages: can produce complex shapes, can be used with a wide range of metals, can produce parts with good surface finish
Limitations: may have porosity or other defects, can be expensive for small production runs

Forging is a process of shaping metal using localized compressive forces
Types of forging: open die forging, closed die forging, impression die forging
Advantages: can produce parts with high strength and durability, can be used to produce parts with complex shapes, can be more cost-effective than casting for large production runs
Limitations: may require significant force and equipment, can be difficult to produce parts with precise dimensions

Sheet forming is a process of shaping and forming metal sheets into desired shapes
Types of sheet forming: bending, drawing, stretching
Advantages: can produce parts with high precision and accuracy, can be used to produce large quantities of parts, can be used with a wide range of metals
Limitations: may require significant force and equipment, can be difficult to produce parts with complex shapes

Welding is a process of joining two metal parts together using heat and pressure
Types of welding: Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW)
Advantages: can be used to join a wide range of metals, can be used to produce strong and durable joints, can be used in a variety of applications
Limitations: may require significant skill and training, can be difficult to produce high-quality joints, can be affected by heat and distortion