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Although these principles have been established primarily through experience, analytical methods, process simulation and 294 To casting have been developed over many years. Because the economics of casting operations are just as important as the technical aspects, this chapter also briefly outlines the basic economic factors relevant toĪs in all manufacturing operations, certain guidelines and design principles pertaining It also describes the characteristics of the alloys that are commonly cast, together with their typical applications. This chapter describes general design considerations and guidelines for metal casting and presents suggestions for avoiding defects. The flow of the molten metal in the mold cavities, the gating systems, the rate of cooling, and the gases evolved all influence the quality of a casting. These variables pertain to the particular characteristics of the metals and alloys cast, method of casting, mold and die materials, mold design, and various process parameters. In the preceding two chapters, it was noted that successful casting practice requires the proper control of a large number of variables. The chapter ends with a discussion of casting economics. The characteristics and applications of the most common ferrous and nonferrous alloys are then described. The chapter describes in detail the design considerations for expendable-mold and permanent-mold casting, and discusses the general guidelines for successful casting operations. This final chapter on metal casting serves as a general guide to important considerations regarding the interrelationships among product design, material, and process selection, as well as economical methods of casting for specific applications. Metal Casting: Design, Nlaterials, and Economics °