A review on casting technology with the prospects on its application for hydro turbines

Casting is one of the oldest manufacturing processes that has been in use since 3400 BC. Over the years, casting technology has evolved tremendously and is one of the most integral parts of ancient history as well as a modern society. The world produced a total of 109.8 million tons of casting in the year 2017, which is a clear indicator of the massive capacity of this industry. Most of it in the current scenario is being used by the automotive industries. Despite being the biggest and the richest industry in the field of energy, hydropower has never been a major market for the casting industry. This might be because the hydropower components are mostly manufactured using other techniques such as machining and rolling. Nevertheless, studies have proven that casting can be used for the manufacturing of several components of the hydropower, especially hydro turbines. Casting technology comes with its own sets of advantages and limitations. This study presents an overview of the status of the casting technology and challenges, the proper optimization in casting that needs to be considered, and the latest technological advancements in this area. This paper aims to develop a theoretical foundation for show-casing the beneficiary, challenges, and possibility of manufacturing hydro turbines through casting technology.