Introduction to Metalcasting


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June 1, 2021


This course introduces the metalcasting process by providing a broad overview of what takes place in a metalcasting facility; illustrating the technology, variables and complexities involved in producing a casting. Course topics include: casting design; alloy selection; process selection; gating and design system; pouring and shakeout methods; cleaning and finishing method; quality assurance; safety and environmental regulations.

The learner will leave the course understanding the basic process of making a casting and key decisions to be made in metalcasting facilities.

Learning outcomes

Class participants will learn to:

  • Define key metalcasting terminology.
  • Identify the current state of the metalcasting industry.
  • Identify the first five casting process areas and one key point from each area.
  • Identify seven alloys used in the metalcasting process.
  • Identify the last five casting process areas and one key point from each area.
  • Describe the difference between pre- and post-casting quality assurance tests.
  • Identify the two agencies regarding environmental health and safety.
  • Actively participate in creating a metalcasting, analyze various case studies, and review a S.W.O.T analysis.

Course Length

2.0 days

CEU Units

1.10 CEU

Course outline

Module 1: Introduction
Module 2: Metalcasting Terminology
  • What is Metalcasting?
  • The Full Process
  • Tour through the Foundry
Module 3: What is the Metalcasting Industry?
  • Metalcasting Statistics
  • S.W.O.T. Analysis
Module 4: Casting Production, Part 1
  • Quoting
  • Design Considerations
  • Tooling
  • Mold Preparation
  • Melting and Pouring
Module 5: Alloys
  • Alloy Basics
  • Alloy Teach Backs
  • Which Alloy?
Module 6: Casting Production, Part 2
  • Casting Removal
  • Degating
  • Port Processing Methods
  • Inspection
  • Shipping
Module 7: Quality Assurance
  • Quality Assurance Tests
  • Casting Defects
Module 8: Environmental Health & Safety Regulations
  • Environmental Protection Agency (EPA)
  • Occupational Safety & Health Administration (OSHA)
Module 9: Putting It All Together
  • Foundry in a Box
  • Case Studies
  • S.W.O.T. Analysis, Part 2
  • Final Activities: Case Studies and Action Plan
  • Summary of Course and Review of Learning Outcomes
  • Complete Course Evaluation
Module 10: Conclusion
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