The process of making non-ferrous castings and their applications

The non-ferrous metal casting process has been around since 3200 BCE, marking the beginning of the Bronze Age. This has made it one of the most influential industrial processes of all time. Over thousands of years of change, the techniques for making non-ferrous castings have evolved alongside the emergence of several new metals, but the concept remains timeless.

When castings are being created, it is crucial to work with an appropriate metal that will satisfy the mechanical requirements as well as look aesthetically pleasing. The high quality of non-ferrous metal castings makes them a preferred choice for fulfilling product development needs.

Non-ferrous metal casting

The casting process for non-ferrous metals is very similar to that for ferrous metals, the primary differences being the purpose of the castings and the materials used.

Metal casting is a complex process in which metal products are formed by pouring molten metal into a mould, where it cools and solidifies. The solidified piece of metal is known as a casting. The process of casting non-ferrous alloys includes preliminary steps to allow for customisation and to suit each client's specific product development needs.

Steps involved in the non-ferrous metal casting process

The initial step in the casting process is creating the mould, with a cavity in the shape of the part to be cast. A core, made of a sand mixture, is used to produce a cavity within the casting. Next, a pattern made of wood or metal acts as a guide for preparing a mould according to the type of casting to be produced.

The metal or alloy to be cast is melted at a high temperature to liquefy it. The liquid metal is then poured into the prepared mould and set aside to solidify. Once the metal has solidified, it is removed from the mould, followed by the process of fettling.

Fettling is all about cleaning the casting and finishing it off by filing the rough edges. The final step in the casting process is quality inspection and, if required, defect analysis.

The different casting processes include sand casting, permanent mould casting, pressure die casting and centrifugal casting.

Applications of non-ferrous castings

Non-ferrous metal and alloy castings are widely used in sectors such as automotive, electrical and general engineering, as well as construction. In the automotive sector, these castings are used in car frames, pumps, air compressors and other parts. In the general engineering sector, they are most commonly found in turbine and supercharger impellers, instrument cases, Freon compressors, torque converter elements, etc.

Due to their light weight, non-ferrous metal castings are used in the construction sector for bridges and roofs where not much strength is required. Similarly, these castings have applications in the electrical sector for supporting structures, motor housings, heat sinks and much more.