Magnetic mould casting technical review

Casting is a critical manufacturing process utilized in numerous industries, influencing the properties of the produced items. This paper addresses the urgent need for innovation in casting techniques to minimize lead-time, reduce production costs while maintaining quality, and lessen environmental impacts. We present magnetic mould casting (MMC) as a promising alternative to traditional casting methods, highlighting its associated benefits. The MMC setup incorporates a wound copper wire acting as a solenoid, creating a magnetic field essential for the casting operation. This study includes the construction of a prototype setup using 19 gauge copper wire, followed by trial runs demonstrating successful casting of aluminium parts. The results indicate that MMC can be scaled up for industrial applications, showcasing advantages such as cost and time efficiency, reduced environmental footprint, and improved properties of the resulting products. Overall, this innovative process merges the benefits of permanent mould and lost foam casting, facilitating the production of intricate shapes with superior surface finishes and minimal machining needs.