UNIT I

CASTING

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 solidified part is also known as a casting

PROCEDURE TO MAKE SAND MOULD

Core Making
A core is a device used in casting and molding processes to produce internal cavities and reentrant angles. The core is normally a disposable item that is destroyed to get it out of the piece.

Types of Core
Green-sand cores Green-sand cores are not a typical type of core in that it is part of the cope and drag, but still form an internal feature. Their major disadvantage is their lack of strength, which makes casting long narrow features difficult or impossible. Even for long features that can be cast it still leave much material to be machined. A typical application is a through hole in a casting. Dry-sand cores Dry-sand cores overcome some of the disadvantages of the greensand cores. They are formed independently of the mold and then inserted into the core prints in the mold, which hold the core in position. They are made by mixing sand with a binder in a wooden or metal core box, which contains a cavity in the shape of the desired core.

Types of Core Boxes

half core box dump core box split core box left and right core box gang core box strickle core box loose piece core box

Moulding Tools

1) Vent wire for sticking vent holes through the sand of the mould. (2) Pattern lifter. (3) Joint trowel (4) heart trowel for smoothing and finishing the parting and flat surfaces of the mould. (5) Gate cutter and pattern lifter. (6) Slick and oval spoon for finishing mould surfaces. (7) Sand lifters (8) slicks. (9) Yankee heel lifter and flat slick. (10) Flange and bead slick. (11) Corner slick. (12) Edge slick. (13) Bound corner slick. (14) Pipe slick. (15) Button slick. (16.) Oval Slick. (17) Hand rammer for ramming sand in flasks (not shown). (18) Spirit level for leveling open sand moulds (not shown).

Ceramic Moulding
This process use a method very near to plaster mold casting. Plaster, plastic, wood, metal or rubber is used for making the pattern. A ceramic slurry comprising zircon, fused silica and a bonding agent is first poured over the pattern. Like rubber it hardens quickly. It is then peeled of the pattern and reassembled as a mold. The volatile materials are removed in a low temperature oven. Ceramic mold, with high temperature pours is obtained after it is baked in a furnace at about 1000 C (1832 F) .

Features of Ceramic Moulding

More accurate in dimension Surface finish is good Wall thickness is small Weights is less Patterns are Reusable and cheap.

Pressure Die Casting

Pressure Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most pressure die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, and tin based alloys, although ferrous metal die castings are possible. The die casting method is especially suited for applications where a large quantity of small to medium sized parts are needed with good detail, a fine surface quality and dimensional consistency.

Pressure Die Casting

Open Hearth Furnace

Electric Furnace

Special Casting Process

CO2 Moulding
CO2 Moulding Carbon dioxide molding is a sand casting process that employs a molding mixture of sand and liquid silicate binder. The molding mixture is then hardened by blowing carbon dioxide gas through it. This method offers a great deal of advantages over other forms of sand molding. It reduces production time as well as fuel costs and reduces the number of mould boxes required for making moulds. This process also offers a great deal of accuracy in production.
At VJP, we utilize these various advantages of carbon dioxide casting to the benefit of the customer. By speeding up the casting process and offering economical solutions, we improve the productivity and profitability of our customers' business. Features High accuracy molding systems incorporating the gas carbon dioxide as a catalyst. Advantages Provides good dimensional tolerances through strong core and mold Provides excellent casting surface finishes Generally used for high-production runs Accommodates a wide range of core and mold sizes. When used for making cores, the CO2 process can be automated for long durations & speedy production runs. Applications Ideal for casting applications where speed and flexibility is paramount.

Shell Moulding

Lost Wax Casting

Casts can be made of the wax model itself, the direct method; or of a wax copy of a model that need not be of wax, the indirect method. These are the steps for the indirect process: Model-making. An artist or mold-maker creates an original model from wax, clay, or another material. Wax and oil-based clay are often preferred because these materials retain their softness. Moldmaking. A mold is made of the original model or sculpture. The rigid outer molds contain the softer inner mold, which is the exact negative of the original model. Inner molds are usually made of latex, polyurethane rubber or silicone, which is supported by the outer mold. The outer mold can be made from plaster, but can also be made of fiberglass or other materials. Most molds are at least two pieces, and a shim with keys is placed between the two halves during construction so that the mold can be put back together accurately. In case there are long, thin pieces sticking out of the model, these are often cut off of the original and molded separately. Sometimes many molds are needed to recreate the original model, especially large ones. Wax. Once the mold is finished, molten wax is poured into it and swished around until an even coating, usually about 1/8 inch or 3 mm thick, covers the inner surface of the mold. This is repeated until the desired thickness is reached. Another method is filling the entire mold with molten wax, and let it cool, until a desired thickness has set on the surface of the mold. After this the rest of the wax is poured out again, the mold is turned upside down and the wax layer is left to cool and harden. With this method it is more difficult to control the overall thickness of the wax layer. Removal of wax. This hollow wax copy of the original model is removed from the mold. The model-maker may reuse the mold to make multiple copies, limited only by the durability of the mold. Chasing. Each hollow wax copy is then "chased": a heated metal tool is used to rub out the marks that show the parting line or flashing where the pieces of the mold came together. The wax is dressed to hide any imperfections. The wax now looks like the finished piece. Wax pieces that were molded separately can be heated and attached; foundries often use registration marks to indicate exactly where they go.

Spruing. The wax copy is sprued with a treelike structure of wax that will eventually provide paths for molten casting material to flow and air to escape. The carefully planned spruing usually begins at the top with a wax "cup," which is attached by wax cylinders to various points on the wax copy. This spruing doesn't have to be hollow, as it will be melted out later in the process. Slurry. A sprued wax copy is dipped into a slurry of silica, then into a sand-like stucco, or dry crystalline silica of a controlled grain size. The slurry and grit combination is called ceramic shell mold material, although it is not literally made of ceramic. This shell is allowed to dry, and the process is repeated until at least a half-inch coating covers the entire piece. The bigger the piece, the thicker the shell needs to be. Only the inside of the cup is not coated, and the cup's flat top serves as the base upon which the piece stands during this process. Prior to silica, a mixture of plaster and fire-proof material such as chamotte was used. Burnout. The ceramic shell-coated piece is placed cup-down in a kiln, whose heat hardens the silica coatings into a shell, and the wax melts and runs out. The melted wax can be recovered and reused, although often it is simply burned up. Now all that remains of the original artwork is the negative space, formerly occupied by the wax, inside the hardened ceramic shell. The feeder and vent tubes and cup are also hollow. Testing. The ceramic shell is allowed to cool, then is tested to see if water will flow through the feeder and vent tubes as necessary. Cracks or leaks can be patched with thick refractory paste. To test the thickness, holes can be drilled into the shell, then patched. Pouring. The shell is reheated in the kiln to harden the patches and remove all traces of moisture, then placed cup-upwards into a tub filled with sand. Metal is melted in a crucible in a furnace, then poured carefully into the shell. If the shell were not hot, the temperature difference would shatter it. The filled shells are allowed to cool. Release. The shell is hammered or sand-blasted away, releasing the rough casting. The spruing, which are also faithfully recreated in metal, are cut off, to be reused in another casting. Metal-chasing. Just as the wax copies were chased, the casting is worked until the telltale signs of the casting process are removed, and the casting now looks like the original model. Pits left by air bubbles in the casting, and the stubs of spruing are filed down and polished.

Investment Casting Process

Investment Casting Process PROCESS BENEFITS OF INVESTMENT CASTINGS (Lost wax) The process is capable of making parts from prototypes to high volume. Investment Casting tooling is capable of making over 1 million parts per tool. Cast tolerance to +/- .005 or better, per inch Cast surface finish of 125 RMS or better Excellent cast details with regards to cast letter i.e. logo, names, part number, etc Reduced machining due to castings designed to near net shape Investment castings can have undercuts, blind holes, thru holes .250 or greater and, almost any geometric shape or size Investment Casting. Often called lost wax casting, is regarded as a precision casting process to fabricate near-net shaped metal parts poured from almost any alloy including: stainless steel, aluminum, brass, bronze and copper. Casting by the investment process allows for parts to meet xray and non destructive testing specifications for: military, aerospace, semi conductor industry, valves, pumps and many other industrial applications. The investment casting process consistently provides high integrity (sound) and dimensionally accurate castings. Cast part dimensions vary less than +-.001 from part to part. Investment casting uses a mold that has been produced by surrounding an expendable pattern with a refractory slurry that sets at room temperature. The pattern (usually of wax or plastic) is then melted or burned out, leaving the mold cavity. Investment casting is also known as the lost wax process? and as precision casting?

Process

Centrifugal Casting

Sand Casting Defects

1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11.

Porosity Fins or Flash on Castings Inclusion(foreign material/sand) in Castings Rough castings Bubbles or Nodules on castings Spalling (an area of the mold wall flakes into the mold cavity) Non fill or Incomplete castings Mould shift Blow Holes Pin Holes Shrinkage cavity

13. Shrinkage cavity 14. Hot Tears (Cracks) 15. Cold shut and misrun 16. Internal Air Pocket

POROSITY
Pattern is improperly sprued. Sprues may be too thin, too long or not attached in the proper location, causing shrinkage porosity. Not enough metal reservoir to eliminate shrinkage porosity. Metal contains gas. Mold is too hot. Too much moisture in the flux. Too much remelt being used. Always use at least 50% new metal. Metal is overheated. Poor mold burnout.

FINS OR FLASH ON CASTINGS

Flask was disturbed while investment was setting. Base was removed too soon. Flask was allowed to partially dry before de-waxing. Incorrect de-waxing or a furnace malfunction. Flask burned out and allowed to cool below (500oF (260oC) before casting reheating, flask allowed to cool between de-wax and placement in preheated oven. Flask was improperly handled or dropped. Speed was set too high on centrifugal casting machine. Patterns were placed on one plane. The should be staggered on top rack. Incorrect water powder ratio was used. Not enough investment was placed over the patterns. Flask was placed too close to heat source in burnout oven. Flasks were not held at low burnout temperature long enough

INCLUSIONS (FOREIGN PARTICLES) IN CASTINGS

Patterns were improperly sprued to wax base or tree or not filleted, causing investment to break at sharp corners during casting. Flask was not sufficiently cured before placing into burnout oven. Improper de-waxing cycle was used. Flask was not cleaned from prior cast. Loose investment in sprue hole. Molten metal contains excess flux or foreign oxides. Crucible disintegrating or poorly fluxed. Improperly dried graphite crucible. Investment was not mixed properly or long enough. Contaminants in wax pattern. Flask was not held at low burnout temperature long enough. Flask was placed too close to heat source in burnout oven.

ROUGH CASTINGS
A poor quality pattern Flask was not sufficiently cured before placing into burnout oven. Flask was held in steam de-wax too long. Metal, flask or both were too hot. Patterns were improperly sprued. Flask was placed too close to heat source in burnout oven.

BUBBLES OR NODULES ON CASTINGS

Vacuum pump is leaking air. Vacuum pump has water in the oil. Vacuum pump is low on oil. Investment not mixed properly or long enough. Invested flasks were not vibrated during vacuum cycle. Vacuum extended past working time.

SPALLING (an area of the mold wall flakes into the mold cavity)
Flask was placed into a furnace at low temperature (below 300oF or 150oC) for an extended period. Flask was placed too close to the source of heat. Sharp corners are struck by metal at high centrifugal velocities. Improper burnout cycle was used.

NON-FILL OR INCOMPLETE CASTINGS

Metal was too cold when cast. Mold was too cold when cast. The burnout was not complete. Pattern was improperly sprued, creating tubulence when csting in a centrifugal casting machine. Centrifugal casting machine had too high revolution per minute.

POROSITY

FLASH
MOULD SHIFT

SHORT CASTING

GAS INCLUSION