Casting is one of the oldest manufacturing methods known to mankind and can be traced all the way back to 5,000bc. Many of the oldest castings still exist today in the form of jewellery and ancient sculptures, which can be found in museums worldwide.
The casting process has come a long way since its application in ancient times and has impacted human civilisation in all aspects of our lives. Cast metal products make up many of the objects which we use on a day to day basis, from industrial vehicles, drills, counterweights, candelabras and wheel hubs. It is a process which is used across a range of industries, from transportation, agriculture, medical and automotive.
Casting manufacturing is the process in which a metal part is formed by pouring molten metal into a mould, where it is then left to solidify. The processes which Majorfax use today are state-of-the-art, but the basic principle has remained unchanged for thousands of years.
The most common casting process used by Majorfax is Sand Casting; this can be split into 5 stages as follows:
- Pattern Making: In order to determine the design of the metal casting, a pattern must be formed. A pattern is a replica of the object to be cast; designed to leave a cavity within the mould where the product will be casted.
- Cores: A hollow casting can be made with a core, which is an additional object shaped and designed to leave an internal cavity.
- Moulding: Once the pattern has been made, the next step is to create a mould around the pattern for casting. Once the mould is formed, the pattern is removed and a cavity will remain, where the molten metal will be poured. These non-reusable moulds are destroyed during the casting process.
- Melting, Pouring and Solidification: There are two types of metals which castings are made from; ferrous (those which contain iron) and non-ferrous. Metals are melted within a furnace at extremely high temperatures, before being poured into the mould. Once poured, the molten metal cools down and solidifies within the mould.
- Cleaning and Inspection: Once the casting has been solidified, the mould is removed and any excess material on the casting is extracted. The casting then undergoes an inspection and quality check to ensure that there are no defects on the product. As part of our process, the casting may be subject to heat-treatment, surface treatment or any additional inspections to meet to the customer’s requirements.