Cold Casting

Cold casting is a metal casting method based on die casting method that workers mix real metal powders such as brass, copper, aluminum, bronze, or other appropriate metal powders. Those used powders are later mixed with resin material and the mixture is poured into a mold or dies in order to generate a protruding three dimensional casting objects that looked like metals. The cold chamber spaces is not heated, so if compared with real metal casting achieved at foundries, cold casting metal casting process could reduce the expenses of costs and time consumption.


Mixed Resins in Cold Casting

Resin materials are so critical to the cold casting that without this component, the entire process cannot be done. In the field of polymer chemistry, resin is a solid and viscous substance of synthetic origin that is often convertible into polymer materials. High viscosity is the basic nature of most resins, and this strong strength that can connect ingredients together is highly appraised by users in many different industrial sectors. The selection of resin materials is highly customized and the process is done by experts, since the viscosity values of the resin and the corresponding physical and chemical parameters all interact with the metal powders as a whole. Experienced cold casting workers know how to deal with the resin issues as well as the process, and they will make the better usages of those viscose materials. 


The Nature of Casting and Cold Casting

Casting of materials such as metal is a very ancient technology human acquired in the history and the recorded oldest surviving casting site can be dates back to about 6800 years old in Asia. Metal casting is a production process in which a liquid-state material is usually poured into a mold like cavity, which normally contains a hollow cavity of the desired shape profile. After the pouring of the liquid, the substance is then allowed to solidify. After that, the solidified part is known as a casting, which is ejected or broken out of the mold object items to complete the entire casting process. Casting can be cold and heated, since the processes are based on the needs of the users. The subject of the article is about cold casting, which is similar to other cold forming methods that are conducted under normal room temperature values.

According to the basic physics, all the casting materials are usually metals or various time setting materials that would cure after mixing more than three or even more components altogether. For instance, things like epoxy, concrete, plaster and clay are good demonstrations of the casting methods. Casting is most often used for making complex shapes that would be difficult or not economical to make by other methods such as cutting and conjoining. Further, ductile casting is also known as ductile cast iron, nodular cast iron, and SG iron; this is a type of graphite-rich cast iron discovered in 1943 by an American metallurgical engineer and inventor Keith Millis. While most varieties of cast iron are weak in tension and brittle, ductile iron has much more impact and fatigue resistance natures integrated, thanks to its nodular graphite inclusions. In addition, ductile iron is not a single material but part of a group of materials which can be produced with a wide range of properties through control of their microstructure frame.

The cold chamber of the cold casting process is not an extraordinary space but rather, the cavity that allow the liquid state materials to solidify so that the casting process can be processed and eventually achieved. In regard to the weight values of the cold casted objects, the weight will be considered lighter if one compared that piece with the hot casted ones with the same surface area. Therefore, there are methods to enhance the weight of cold casted metals such as by adding some other additive matters. With the additive materials, the casted materials are much more real to the viewers if they are used as the prototypes. Some other experts also compare cold casting with 3D printing methods, but the comparison may be little bet not the same, yet these are two three dimensional metal working methods that can make use of the given materials with a relatively lower expenses.

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