Metal Casting presents a great opportunity for artists and hobbyist as it gives them a certain amount of control and creative license with regards to the end result. Metal Casting is an ancient practice that is still used to this day in industries such as manufacturing airplane components to small scale hobby casting.
The casting process which is so crucial to the entire form is where one takes melted metal and creates an object based on a pattern by using a mold. On first glance the entire casting process seems complicated and even convoluted but with a little patience and time, most of which will be spent reading, the process involved in metal casting can be understood and even mastered.
Metal casting does take technical know how and skill. Luckily, you do not have to be born with a golden furnace to cast. This means that if you have the will, not to mention the mold and the furnace and all the other tools, you have the way.
Since each casting method differs slightly from the other, it is advised to read up on it before you try your hand at the technique. The most common casting method is sand casting which is probably the best way to start out a metal casting career. What I will attempt to do is to provide a general overview of the basics in metal casting. The specifics for each casting process will differ of course since, for example, Investment casting uses wax and not sand and die casting uses centrifugal force where most other casting processes do not. So, it will be important to research the process involved with each individual casting type but it is always great to have a base to build from.
The casting process for most forms will include making the pattern, making the core, if one is needed, molding and the actual melting of the metal, pouring, and then finishing it all off by cleaning.
Pattern making is the first step in any casting process. You will have to first determine what is needed for your project. The pattern is considered the original and can be any needed shape from a bolt to a figure of a horse. If the object being made is hallow or has parts with holes or other empty spaces, you will need to make a core. The core is inserted into the mold so that the casting can take the appropriate shape and that metal does not fill in areas that should be left empty. The core is collapsible so it can be removed after the casting process without any damage to the finished product.
The molding contains the flask which is created by an upper half or the cope and the lower half which is the drag. In the sand casting process, sand is packed into the molding where the pattern is placed. Once the sand is rammed or packed the pattern is removed then preparations can be made for pouring.
Depending upon the kind of metal and the type of furnace the melting step will vary. The Crucible is what the metal is melted in and the Crucible handling tools will allow you to safely move the crucible to the mold where you will pour the molten metal. You will allow the metal to solidify, and then remove the mold very carefully.
During cleaning you will be removing any excess bits and pieces on the finished product and in essence, make it nice and clean, and ready for whatever intended purpose you had in mind.
The casting process is a lengthy one involving many steps, beyond the general ones stated here. For this purpose it will be important for you to do some reading and some research so that your attempts at casting will come out just as you would like.
