How Metal Casting Works: From Molten Metal to Finished Piece

Metal casting is one of the most flexible and reliable manufacturing methods available. It allows items with complex geometry, heavy sections, and specific material properties to be produced efficiently.

At a sand foundry working with ferrous and non-ferrous metals, the casting process follows a series of controlled steps designed to ensure quality and repeatability.

Architectural metal lacework created in a foundry.

Step 1: Selecting the right metal or alloy

Every successful casting begins with choosing the appropriate material. Factors such as load, wear, corrosion exposure, temperature, and expected service life all influence metal or alloy selection. Non-ferrous alloys are often chosen for their corrosion resistance and predictable performance.

Step 2: Pattern and mould preparation

A pattern (replica) of the desired item is made and then used to create a mold cavity. The mold based on the pattern must be accurately produced to ensure dimensional consistency of the metal casting.

Step 3: Melting the metal

The selected metal or alloy is melted in a furnace at carefully controlled temperatures. Proper melting is critical to ensure good metal flow, minimise defects, and achieve the desired properties of the cast item.

Step 4: Pouring and solidification

Once molten, the metal is poured into the mold. As it cools, the molten solidifies into the exact shape of the mold cavity. Controlled cooling helps achieve the required strength and structural integrity.

Step 5: Finishing and inspection

After cooling, the casting is removed from the mold and finished. This may involve trimming, machining, surface treatment, and inspection to ensure it meets specifications.

Why metal casting remains widely used

Metal casting remains a popular because it is a versatile, efficient, and cost-effective method for producing metal items. It allows complex shapes to be formed with excellent strength, durability and material efficiency.

Furthermore, metal casting is a scalable manufacturing process, with the same basic principles applying whether producing a single custom-made item or heritage replacement part, medium-volume industrial run, or hundreds of identical components.

Foundries across Adelaide and Australia continue to rely on casting to support essential industries as well as government, commercial and domestic works.

Have a piece that needs to be cast or replaced?

At Adelaide Brass Castings, our foundry team can help assess materials, manufacturing methods, and feasibility for custom or replacement items.

Get advice on your metal casting project. To contact us, simply click here or email admin@abcast.com.au.