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direct molding method is to make the wax material into the same wax mold as the casting by hand or other tools; the indirect molding method is to make the wax mold through the mold. The direct molding method requires craftsmen to have a high technical level, otherwise the quality of castings cannot be guaranteed. However, the limitation of manual direct molding is that its efficiency is too low to achieve mass production. In this regard, indirect moulding has advantages. In indirect moulding, artisans usually make moulds from stone, wood, clay or other plastic materials.
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applied to the surface. For example, painting and etching can be used in a way that give the appearance of metal or stone. Alternatively, the material is altered in its initial casting process and may contain colored sand so as to give an appearance of stone. By casting concrete, rather than plaster, it is possible to create sculptures, fountains, or seating for outdoor use. A simulation of high-quality marble may be made using certain chemically-set plastic resins (for example
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have been developed to perform some of the more repetitive parts of the fettling process, but historically fettlers carried out this arduous work manually, and often in conditions dangerous to their health. Fettling can add significantly to the cost of the resulting product, and designers of molds seek to minimize it through the shape of the mold, the material being cast, and sometimes by including decorative elements.
75:. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. Heavy equipment like machine tool beds, ships' propellers, etc. can be cast easily in the required size, rather than fabricating by joining several small pieces. Casting is a 7,000-year-old process. The oldest surviving casting is a copper frog from 3200 BC.
167:
143:(1600-1040 BC) while a large amount (100,000 pieces) of piece-mould fragments were found. This led to the conclusion that lost wax was not performed in the capital during this dynasty. However, the discovery of a mask made using the investment moulding dated at around 1300 BC indicated that the lost wax technique may have influenced other regions in China.
131:
to mass produce the new copper coins. Introduced was a multi piece stackable coin template mold. Multiple molds were placed on top of one another into a clay cylinder so molten metal could be poured down the center, filling and solidifying in the open spaces. This process allowed one hundred coins to be produced simultaneously.
83:
Throughout history, metal casting has been used to make tools, weapons, and religious objects. Metal casting history and development can be traced back to
Southern Asia (China, India, Pakistan, etc). Southern Asia traditions and religions relied heavily on statue and relic castings. These items were
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and distortion. Simulation accurately describes a cast component's quality up-front before production starts. The casting rigging can be designed with respect to the required component properties. This has benefits beyond a reduction in pre-production sampling, as the precise layout of the complete
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Historians debate the origin of the development of the cannon but most evidence points to Turkey and
Central Asia in the 18th and 19th century. The casting process of a cannon is a bit more complex with the use of a clay core, a template which has clay moulded around it and then broken out followed
134:
In the Middle East and West Africa the lost wax technique was used very early in their metallurgy traditions while China adopted it much later. In
Western Europe lost wax techniques are considered to have been hardly used especially in comparison to that of the Indus valley civilization. There were
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India is attributed as one of the first civilizations to use casting methods to mass produce coins. Around the middle of the first millennium BC (1000 BC - 1 BC), coins used were made from silver but as the millennium progressed the coins shifted to a cast copper alloy. New technology was developed
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Raw castings often contain irregularities caused by seams and imperfections in the molds, as well as access ports for pouring material into the molds. The process of cutting, grinding, shaving or sanding away these unwanted bits is called "fettling" in UK english. In modern times robotic processes
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molds as noted above, multiple-use 'piece' molds, or molds made of small rigid pieces or of flexible material such as latex rubber (which is in turn supported by an exterior mold). When casting plaster or concrete, the material surface is flat and lacks transparency. Often topical treatments are
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in the ancient city of Sparta, Babylon, which specifically records how much wax is needed to cast a key. The earliest-known castings in the global archaeological record were made in open stone molds. There are two types of lost wax methods, direct lost wax method and indirect lost wax method. The
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that enable the metal to fill the mold. The mold and the metal are then cooled until the metal solidifies. The solidified part (the casting) is then recovered from the mold. Subsequent operations remove excess material caused by the casting process (such as the runners and risers).
227:) with powdered stone added for coloration, often with multiple colors worked in. The latter is a common means of making washstands, washstand tops and shower stalls, with the skilled working of multiple colors resulting in simulated staining patterns as is often found in natural
55:, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various time setting materials that
122:
is a copper alloy casting that most likely utilizes the lost wax technique. Lost wax casting can be dated back to 4000 BC or the
Chalcolithic period. One of the oldest studied examples of this technique is a 6,000-year old amulet from
314:, commercial programs (such as PoligonSoft, AutoCAST and Magma) are available which make it possible for foundries to gain new insight into what is happening inside the mold or die during the casting process.
640:
Thoury, M.; et al. (2016). "High spatial dynamics-photoluminescence imaging reveals the metallurgy of the earliest lost-wax cast object". Nature
Communications. 7. doi:10.1038/ncomms13356.
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the majority of castings were simple one to two piece molds fashioned from either stone or ceramics. However, there is evidence of lost wax castings in numerous ancient civilizations.
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In metalworking, metal is heated until it becomes liquid and is then poured into a mold. The mold is a hollow cavity that includes the desired shape, but the mold also includes
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for the simulation of casting processes provides opportunities for an interactive or automated evaluation of results (here, for example, of mold filling and solidification,
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Early civilizations discovered lead aided in the fluidity of molten copper, allowing them to cast more intricate designs. For example, the dancing girl of
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The software supports the user in component design, the determination of melting practice and casting methoding through to pattern and mold making,
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Aspects of
Ceramic History: A Series of Papers Focusing on the Ceramic Artifact As Evidence of Cultural and Technical Development
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156:
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447:
909:
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310:, and is regarded as the most important innovation in casting technology over the last 50 years. Since the late '
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545:
Craddock, Paul T (October 8, 2014). "The Metal
Casting Traditions of South Asia: Continuity and Innovation".
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Plaster and other chemical curing materials such as concrete and plastic resin may be cast using single-use
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Casting process simulation was initially developed at universities starting from the early '
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and cooling, and provides a quantitative prediction of casting mechanical properties,
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by an assembly in a casting pit that involves binding the casting with iron bands.
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295:, and finishing. This saves costs along the entire casting manufacturing route.
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Jane L. Bassett; Peggy
Fogelman; David A. Scott; Ronald C. Schmidtling (2008).
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342: – Casting technique that is typically used to cast thin-walled cylinders
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110:. The earliest known record of lost-wax casting is a clay tablet written in
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Manufacturing process in which a liquid is poured into a mold to solidify
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390:(process) - Sand casting process with use of plaster to fill gaps
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to calculate cast component quality considering mold filling,
177:. Concrete cast of books on library shelves turned inside out.
408: – Metal casting process using sand as the mold material
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The
Craftsman Revealed: Adriaen de Vries, Sculptor in Bronze
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process in which a liquid material is usually poured into a
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after mixing two or more components together; examples are
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486:
Davey, Christopher J. (2009). J. Mei; Th. Rehren (eds.).
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Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003),
396: – Metal casting process that employs reusable molds
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Craftsman's
Illustrated Dictionary of Construction Terms
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Metalworking in Bronze Age China: The Lost-Wax Process
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N. Hansen, Erwin Flender and Jörg C. Sturm. (2010).
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The Long History of Lost Wax Casting, Gold Bulletin
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157:List of manufacturing processes § Casting
135:no pieces of lost wax found in the capital of
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830:"Thirty Years of Casting Process Simulation"
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712:Fundamentals of Manufacturing For Engineers
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106:The lost wax process originated in ancient
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628:Lost-wax Casting: A practitioners manual
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440:Materials and Processes in Manufacturing
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88:laced with lead. Since the beginning of
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688:. PHI Learning Pvt. Ltd. pp. 92–.
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834:International Journal of Metalcasting
573:. Getty Publications. pp. 269–.
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488:The early history of lost-wax casting
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791:. Gregg Revivals. pp. 284–285.
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547:Indian Journal of History of Science
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442:(9th ed.), Wiley, p. 277,
744:. Craftsman Book Company. pp.
200:Plaster, concrete, or plastic resin
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817:. Louis Cassier. 1971. p. 80.
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288:, material, and tooling savings.
866:from the original on 2020-05-26.
788:A History of Labour in Sheffield
709:T F Waters (11 September 2002).
661:. Gordon Elliott. pp. 52–.
340:Centrifugal casting (industrial)
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284:casting system also leads to
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715:. CRC Press. pp. 17–.
615:. Cambria Press. p. 5.
490:. London. pp. 147–154.
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626:Feinberg, Wilburt (1983).
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19:For molding plastics, see
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28:Casting (disambiguation)
910:Casting (manufacturing)
881:Campbell, John (2003),
785:Sidney Pollard (1993).
736:James T. Frane (1994).
655:Gordon Elliott (2006).
173:(Nameless Library), by
84:frequently made from a
771:The British Foundryman
394:Permanent mold casting
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225:thermosetting polymers
183:Casting (metalworking)
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466:(1st ed.), PHI,
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915:Sculpture techniques
594:Hunt, L. B. (1980).
26:For other uses, see
774:. 1986. p. 80.
609:Peng, Peng (2020).
256:A high-performance
846:10.1007/BF03355463
364:Investment casting
332:Engineering portal
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318:See also
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