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Slide 26 of 69
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Casting not only produces the the billet and cake for all the other manufacturing processes, but is used to produce components.
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There are a variety of casting processes but essentially molten liquid metal is poured into a shaped mould.
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Sand cast moulds as inferred are made from sand bonded with clays and silicates, shell moulds are made from sand coated with thermosetting resin which is allowed to fall on to heated metal pattern plates. After a short time these are inverted and the excess sand falls away leaving a shell of sand adhering to the pattern. The shell is baked to harden the resin, resulting in a easily handled strong biscuit from which moulds are assembled. The molten metal is then poured into the mould and allowed to solidify before the sand is broken away to reveal a finished casting replicating the cavity in the sand moulds.