DIY Metal Casting is more than just an excuse to play with molten metal it is actually a great way to create art and complicated pieces of machinery or other items that would otherwise be nearly impossible to make. Metal Casting is really a great way to save money...while playing with molten metal.
The reason that Metal Casting has survived the test of time is a matter or efficiency. Some of the earliest casting examples have been found in China dating back thousands and thousands of years. In fact every major civilization from the Egyptians to the Romans practiced metal casting. This skill came back into vogue during the Renaissance and has continued to advance and evolve from there. Its hard to remember that there are a lot of other casting processes because sand casting is used the most often.
Not everyone is going to be casting heavy pieces like engine parts or cast their own motorcycles. So for those that just want to make decorative pieces you will not be using the same casting process as these heavy duty casters. For artists creating small scale statues or embellishes and for hobbyists that need a decorative touch to their model plane or boat might want to consider using gravity casting for their needs.
Gravity casting seems to be especially useful when dealing with aluminum and other light alloys. The name "casting" or "metal casting" really describes exactly what the task itself is. The metal is introduced into the mold by the force of gravity. Most other casting process either use natural pressure difference like the kind in certain sand casting procedures or they use forced pressure like in centrifugal casting to get the molten metal into the mold.
One of the most common uses for Metal Casting is when permanent molds are going to be used. Also called a die, the permanent mold is really only economical for those planning on using the same mold numerous times and will need to keep the quality at a constant level. You can reuse molds but you need to be careful because the quality can really go down each time you use the mold. With die molds the quality will remain the same. Its a good idea to think of Die molds as a long term investment. Yes, they will be more costly then other molds; however they will outlast cheaper options for molds. Permanent molds are created using a variety of metals including cast iron and steel.
Gravity casting is used for the permanent mold process with pleasing results. Gravity casting is usually used when the finished product is more visually based then structurally based which is why this method is a favorite of artists and even some jewelers. The loss of strength is due to the lack of pressure used in this process. For those that need the strength but still want to use gravity casting, more of the molten metal will need to be used which will increase the weight.
Relying on gravity will take patience, although it will be needed for larger products.
If you have never tried gravity casting then you should, because you just may be surprised by what such a simple thing like gravity can create. For the sake of humor, make an apple and see what happens.
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