# 1 Control Over Material Shape:
Because a casting is not limited like an assembly or weldment by setting things off with raw material shapes. You can put the material where it’s required in certain areas of high stress and minimize the material in areas where it’s required.
This capability provides excellent control to the industrious engineer, while also providing both aesthetic as well as weight-saving advantages.
# 2 Isotropic Properties vs. Directional Properties
Weldments and assemblies undergo anisotropy meaning that a component has ductility and strength in the working direction but has reduced transverse properties. In short, the orientation of the microstructure of the material will impact the stiffness and strength of the material differently based on the orientation of the stresses that are applied, thereby affecting direction of propagation and crack formation.
Cast components don’t have directionality which causes confidence in an increased strength, toughness and ductility than may be associated with a fabricated or welding component.
While design fabricators should focus only on the directional properties of the materials they are working upon and include them into the design of the component (lest the final product turns out to be overstressed on the application of the load in the transverse direction), casting designers have considerably increased flexibility.
Better Conformance, Repeatability and Quality:
Upon conversion of weldment to casting it eliminates many of the variables intrinsic to a manual process such as welding. Insufficient weld size joining material, missed welds, pin holes and porosity in weld joints and inconsistency in process or weld beads are all got rid of. As the casting is made of the same production tooling every single time, the casting process provides excellent consistency. This improved consistency changes itself directly to the field where rates of failure are minimized.
While customer discussion often revolves around the casting’s cost-saving benefits in terms of cost-per-part, it is a good point to note the minimization of liability resulting out of manufacturing a much reliable part. Remember the litigation costs in the case of failed weld will spring a surprise no company would ever want.