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Introduction to Casting Processes Classification of Casting Processes Fundamentals of Casting Analysis of Casting Process Types of Casting Processes
Expendable-mould Casting Processes Permanent-mould Casting Processes

Inspection of Castings Melting Practice & Furnaces Recommended texts

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Classification of Casting Processes

Casting Processes

Expendable Mould

Permanent Mould

Expendable Pattern

Permanent Pattern

Ex: Investment Casting Lost pattern "

Ex: Sand Mould Casting Shell " "

Ex:

Pressure-Die Casting
Slush "

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Introduction to Casting Processes

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Casting??

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 Casting is a process which

basically involves pouring of molten metal into a mold cavity where, upon cooling down & solidification, it takes the shape of the cavity.

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History of Casting

Ancient Greece: Bronze statue casting, about 450 BC

Europe: Cast iron Cannons from England, about 1500 AD

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History of Casting in Sri Lanka

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Automobile industry Ship-building industry Aerospace industry Manufacturing industry Household appliances Etc.

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Why Casting?
Intricate of shapes May be cast in a single operation. Some metals can only be cast to shape Resistance to working stress Construction may be simplified, no assembly. Mass production at high production rates. Very large, heavy metal objects may be cast Good engineering properties
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What are the limitations in Casting?

Surface finish & dimensional accuracy. Limitations in toughness & strength. Limitations in making thin & complex structures. Shrinkage & porosity. Casting defects

Casting is a net-shape manufacturing process

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What is net-shape manufacturing?

Processes by which part is made, in the first operation, as close to the final desired dimensions, tolerances, surface finish, & specifications.

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Cast Items
Exhaust manifold using sand casting

A cast transmission housing using sand casting

Cast items using investment casting

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Cast Items
Typical Gray-iron castings used in automobiles, including transmission valve body (left) & hub rotor with diskbrake cylinder (front).

Two-piece Polaroid camera case made by the hot-chamber die casting process.
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Turbine blade using Permanent mould casting

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Types of materials used for Casting

Ferrous metals
Cast iron, Wrought iron, Alloy cast iron, Steel, etc.

Non-ferrous metals
Copper alloys, Aluminium alloys, Magnesium alloys, Tin alloys, etc.

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Limitations to selection of materials

Fluidity Shrinkage Ease with which properties can be controlled

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Foundry
What is a Foundry?
Is a workshop dedicated for metal casting.

How foundries are classified?

Based on the metal to be cast
Steel foundry Cast iron foundry Light alloy foundry Brass foundry

Based on the type of work

Jobbing foundry which specialize in small orders for wide variety of engineering shapes Repetition foundry for mass production of large numbers of identical castings of a particular shape & composition.
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Summary Introduction to Casting

Overview of Casting History of Casting Typical applications of Casting Advantages of Casting Limitations of Casting Casting Materials Foundry
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Fundamentals of Casting

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Terminology in Casting

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Examples of Casting

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Basic requirements of casting process

Mould Cavity Melting Process Pouring Techniques Solidification Process Mould Removal Cleaning, Finishing & Inspection

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Should be of desired shape & size Ability to compensate shrinkage of the solidifying metal Must be able to reproduce the desired detail Must have refractory characteristics

Mould Cavity

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Types of Moulds
Expandable Moulds Permanent Moulds Composite Moulds

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Expendable Moulds
Usually made of
sand, plaster, ceramics, etc & mixed with various binders or bonding agents.

After the casting has solidified, the mould is broken up to remove the casting Preferred for production of smaller quantities
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Types of Expendable Moulds

Expendable mould with re-usable pattern Expendable mould with disposable pattern

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Example: Sand Mould

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 Pattern Core

Casting Terminology

Approximate duplicate of the casting, when the pattern is withdrawn, its imprint provides the mould cavity. Placed into a mould cavity to form the interior surfaces or features of castings.

Moulding material
Readily formed aggregate material, which is packed around the pattern.

Flask
Rigid wood or metal frame that hold the moulding aggregate.

Cope
Top half of the pattern, flask, mould or core of a two-part mould.
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 Drag
Bottom half of any of the above features

Core print
Region that is added to the pattern, core, or mould & is used to locate & support the core within the mould.

Mould cavity
Combination of mould material & core produce a shaped hole.

Riser
An extra void created in the mould to hold molten metal, that acts as a reservoir of liquid that can flow into the mould cavity to compensate for any shrinkage.

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Gating system
Network of connected channels used to deliver the molten metal to the cavity.

Vent
Additional channels to provide an escape for the gasses that are originally present in the mould or generated during the pour.

Parting line
Interface that separates the cope & drag halves of mould, flask, core or pattern.

Draft
Taper on a pattern or casting that permits it to be withdrawn from the mould.
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Core box
Mould or die used to produce cores.

Sprue
Vertical portion of the gating system.

Choke
Cavity in the mould at the base of the Sprue to allow the metal to flow smoothly.

Runners
Horizontal channels.

Gate
Controlled entrance.

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Permanent Moulds
Usually made of metals Used repeatedly Designed in such a way that the casting can be easily removed Generally restricted to large production

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Advantages of Permanent Moulds

Good surface finish Good dimensional accuracy High strength & thermal conductivity

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Composite moulds
Made of two or more different materials, such as sand, graphite & metal Combined advantages of each material

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Melting process
Providing molten metal at proper temperature with desired quantity with acceptable quality with reasonable cost

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Melting temperatures of metals

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Pouring Techniques
Introduces the molten metal into the mould cavity Escape of all air or gases in the mould Controlled pouring rate of the molten metal

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Solidification Process
Proper heat removal rate is required Affects properties of the cast Shrinkage must be compensated

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Mould Removal
Mould is destroyed in expendable moulds during removal of the casting. Permanent moulds are retained, thus require ejector systems to remove the casting.

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Cleaning, Finishing & Inspection

Extraneous material must be removed. Minor finishing operations Further processing Inspection for cast defects & the overall quality of the cast product.

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Summary: Fundamentals of Castings

Terminology in Casting Basic requirements of casting processes
Mould cavity
Types of moulds Casting terminology

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Melting process Pouring technique Solidification process Mould removal Cleaning, Finishing & Inspection
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