Name: Kim Mendez Mark Aliguin Activity No.

2 Aluminum Casting Objectives: After the experiment, the student will be able to: 1. 2. 3. 4. Perform the basic procedure on mixing plaster of paris Perform the basic melting of aluminum Execute the steps on casting aluminum in a mold Enumerate the benefits and limitations of casting in the society

Date: July 8, 2013

Materials/Equipment: Plaster of Paris Mold Aluminum Furnce Rod Thongs Procedure: A. Making a mold 1. Prepare the mixing container with water. Ratio should be 2 parts powder 1 part water. 2. Start adding the Plaster of Paris powder to the water in your mixing container by sprinkling or sifting the powder over the water. Do not add powder in one spot, instead try to cover as much area as you can. 3. Do not mix yet. Instead, tap the side of your mixing container with a spoon to disperse the powder into the water and remove any air bubbles. 4. Gently mix the Plaster of Paris mixture from side by side until it reaches a uniform and smooth consistency. Do not stir vigorously to avoid any air bubbles from forming. 5. Put your molder to the surface and let it dry. B. Melting and casting of aluminum 1. 2. 3. 4. 5. Cut the aluminum metal into small sheets. Slowly put the cut aluminum sheets in the crucible and stir using the rod. Seal the crucible and wait until it reaches its melting point. (800 C) Slowly pull the crucible up and immediately pour to the mold to avoid solidification Let the aluminum cool before pulling out in the mold.

ILLUSTRATIONS: MOLD:

ALUMINUM CAST:

Data and Results: 1. What is casting? What is the most common metal used in casting? Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries 2. What is the best way to remove the impurities in the molten aluminum? Where do these impurities come from? Refining is done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made

3. Give the advantages and disadvantages of casting aluminum using the laboratory melting furnace: Advantages Disadvantages Small amount of aluminum can be melted in the crucible. Pouring rate is not being controlled. The relative fluidity of a certain metal casting melt cannot be quantified Gases are present in the crucible and gases are absorbed by molten metal. Pressure is not being controlled.

4. What is shrinkage? When does this occur? Most materials are less dense in their liquid state than in their solid state, and more dense at lower temperatures in general. Due to this nature a metal casting undergoing solidification will tend to decrease in volume, during the manufacture of a part by casting this decrease in volume is termed shrinkage. Shrinkage occurs when Decreased volume of the liquid as it goes from the pouring temperature to the freezing temperature, Decreased volume of the material due to solidification and Decreased volume of the material as it goes from freezing temperature to room temperature

5. List down at least five (5) safety precautions while performing the activity. References:
http://en.wikipedia.org/wiki/Foundry http://thelibraryofmanufacturing.com/metalcasting_operation.html http://en.wikipedia.org/wiki/Foundry

Wear goggles to protect your eyes. Always seal the crucible.