Cast parts

What are metal castings?

Metal castings are precision-manufactured components produced by pouring liquid metal into a mould. This process allows the production of complex geometries with high dimensional accuracy and excellent mechanical properties. Metal castings are used in numerous industries, including mechanical engineering, the automotive industry and aerospace.

Manufacturing processes for metal castings

Metal castings are manufactured using various casting processes, which vary depending on the material, batch size and required quality:

Sand casting

This process is particularly flexible and is suitable for small to medium-sized series. It allows the production of large and complex components, but offers lower surface quality compared with other casting processes.

Investment casting

Investment casting, also known as the lost-wax process, is used for highly precise components with fine details. It enables thin-walled, highly complex structures with excellent surface quality.

Gravity die casting

Here, the metal is poured into a reusable permanent mould, which enables improved dimensional accuracy and higher production speed. Gravity die casting is particularly suitable for medium and large-scale production runs.

Die casting

Die casting is ideal for the mass production of precise and high-strength castings. The metal is pressed into a mould under high pressure, achieving excellent surface properties and tight tolerances.

Materials for metal castings

Depending on the area of application, various metals and alloys are used:

• Aluminium casting – Light, corrosion-resistant and particularly in demand in the automotive and aerospace industries.
• Steel casting – High strength and wear resistance, often used in mechanical engineering.
• Grey cast iron – Good damping properties and cost-efficient in production.
• Brass and bronze components – Corrosion-resistant and particularly suitable for maritime applications.

Quality characteristics and testing methods

High-quality metal castings are characterised by tight dimensional tolerances, smooth surfaces and optimum mechanical properties. Various testing methods are used for quality assurance:

• Dimensional accuracy testing – Ensuring precise dimensions by means of coordinate measuring machines (CMM).
• Non-destructive testing methods – X-ray and ultrasonic testing to detect internal defects.
• Mechanical tests – Hardness, tensile and compression tests to determine the material properties.

Industries and areas of application

Metal castings are essential in numerous industries:

• Mechanical engineering – Manufacture of robust and durable machine elements.
• Automotive industry – Manufacture of engine components, gearbox housings and structural parts.
• Aerospace – Production of light but high-strength components.
• Medical technology – Precise castings for surgical instruments and implants.

Sustainability and recycling of metal castings

Metal castings are particularly sustainable, as they are fully recyclable. Modern foundries rely on energy-efficient processes and closed material cycles in order to minimise environmental impact.

Choosing the right manufacturer

When choosing a foundry, the following factors should be taken into account:

• Experience and specialisation – Expertise in processing certain materials and casting processes.
• Certifications – Compliance with international quality standards such as ISO 9001 or IATF 16949.
• Manufacturing capacities – Ability to produce both small and large series.
• Consulting and development – Support in optimising component designs for more economical production.