Exploring Metal-Casting Processes

What is metal casting?

• A process of recycling old metal into new forms.

• A technique for welding metal pieces together.

• A method of shaping metal using high temperatures without molds.

• Metal casting is a manufacturing process that involves pouring molten metal into a mold to create objects.

Name three common metal casting processes.

• sand casting, investment casting, die casting

• welding

• plastic molding

• forging

What is the main purpose of a mold in casting?

• To shape molten material into a specific form.

• To mix different materials before casting.

• To store the finished product after casting.

• To cool down the molten material quickly.

Describe the difference between sand casting and investment casting.

• Sand casting is more expensive than investment casting; investment casting is used for large structures.

• Sand casting is for larger, less detailed parts; investment casting is for high precision and intricate designs.

• Sand casting is a method for creating glass products; investment casting is for metal parts.

• Sand casting is used for jewelry making; investment casting is for construction materials.

What materials are typically used for making molds?

• Concrete, fabric, leather, foam

• Stone, clay, vinyl, carbon fiber

• Wood, glass, paper, rubber

• Metals, plastics, silicone, ceramics

Explain the term 'pouring temperature' in metal casting.

• The temperature at which metal solidifies in the mold.

• The temperature of the mold before pouring the metal.

• The temperature at which metal is cooled after casting.

• The temperature at which molten metal is poured into a mold during casting.

What is the role of a riser in a casting process?

• The role of a riser in a casting process is to supply additional molten metal to compensate for shrinkage during solidification.

• To shape the final product after solidification.

• To cool the molten metal quickly.

• To provide a mold for the casting process.

How does the cooling rate affect the properties of the cast metal?

• The cooling rate influences the microstructure, hardness, and ductility of cast metal.

• Cooling rate only affects the color of the cast metal.

• A slower cooling rate always increases brittleness.

• The cooling rate has no effect on the metal's properties.

What are the advantages of using die casting?

• Limited design flexibility

• Poor surface finish

• Low production rates

• Advantages of using die casting include high production rates, excellent dimensional accuracy, ability to produce complex shapes, smooth surface finish, and cost-effectiveness for large runs.

What is the significance of gating systems in casting?

• Gating systems control the flow of molten metal, reduce defects, and ensure uniform filling of molds in casting.

• Gating systems are used to cool the metal after casting.

• Gating systems are primarily for aesthetic purposes in casting.

• Gating systems are only necessary for large-scale industrial casting.