title = "Casting Processes Overview"

content = """
Casting is the process of pouring molten metal into a mold cavity and allowing it to solidify into
a desired shape. Ridgecrest Metalworks operates foundry and casting capabilities that allow the
facility to produce components ranging from small precision castings to large structural members
weighing several hundred pounds. Understanding the range of available casting methods helps production
teams select the appropriate process for a given part geometry, material, production volume, and
dimensional requirements.

Casting processes differ primarily in how the mold is made, the mold material, and how the molten
metal is introduced. Key process characteristics to consider:

Mold Type: Expendable molds (destroyed after each casting, as in sand casting and investment casting)
allow more complex internal geometries through the use of cores. Permanent molds (reusable metal
tooling, as in die casting) offer dimensional repeatability and faster cycle times but are limited in
complexity and material choice.

Pouring Method: Gravity pouring (metal enters under gravity) is the simplest approach and is used in
sand casting and permanent mold casting. Pressure-assisted filling (die casting) enables faster fill
of thin-walled sections but requires high-pressure tooling. Centrifugal casting uses rotational force
to fill the mold, producing near-zero porosity in cylindrical forms such as rings and pipes.

Material Compatibility: Sand casting is compatible with virtually all metals. Die casting is typically
limited to non-ferrous alloys (aluminum, zinc, magnesium) because ferrous metals at steel casting
temperatures would erode the steel die tooling rapidly.

Processes in Use at Ridgecrest:
- Sand casting: The primary foundry process for steel, ductile iron, and some aluminum castings
- Investment (lost-wax) casting: For precision near-net-shape parts in stainless, alloy steel, and
  superalloys; operated in limited quantities for aerospace and industrial customers
- Permanent mold gravity casting: For repetitive aluminum castings with moderate complexity
- Continuous casting: For producing steel and non-ferrous billets and slabs used as forging feedstock

Casting fundamentals — mold preparation, melt treatment, pouring practice, solidification control,
and post-cast cleaning — are addressed in the department's detailed process procedures. All casting
operations must be authorized by a production traveler linked to an approved casting process procedure.
"""

version = "0.0.1"
