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Chapter 11 METAL CASTING San! Casting PR CESSES

ther E"pen!a#$e Mo$! Casting Processes Per%anent Mo$! Casting Processes &oun!r' Practice Casting (ua$it' Meta$s for Casting Pro!uct )esign Consi!erations

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T*o Categories of Meta$ Casting Processes

Expendable mold processes - %o$! is sacrifice! to re%o+e part

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A!+antage, %ore co%p$e" shapes possi#$e )isa!+antage, pro!uction rates often $i%ite! #' ti%e to %a-e %o$! rather than casting itse$f

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3.

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Permanent mold processes - %o$! is %a!e of %eta$ an! can #e use! to %a-e %an' castings

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+er+ie* of San! Casting

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Most *i!e$' use! casting process. accounting for a significant %a/orit' of tota$ tonnage cast Near$' a$$ a$$o's can #e san! caste!. inc$u!ing %eta$s *ith high %e$ting te%peratures. such as stee$. nic-e$. an! titaniu% Parts ranging in si0e fro% s%a$$ to +er' $arge

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&igure 1121 3 A $arge san! casting *eighing o+er 645 -g 61755 $#8 9 for an air co%pressor fra%e 6courtes' E$-hart &oun!r'. photo #' Paragon Inc . E$-hart. In!iana8 ISE 316 - Manufacturing

S E 3 1 6 12

Steps in San! Casting

Prepare %o$! for pour2 Pour %o$ten %eta$ into san! %o$! A$$o* %eta$ to so$i!if' <rea- up the %o$! to re%o+e casting C$ean an! inspect casting =eat treat%ent of casting is so%eti%es re1uire! to i%pro+e %eta$$urgica$ properties

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32

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;2

72

62

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Ma-ing the San! Mo$!

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The cavity in the san! %o$! is for%e! #' pac-ing san! aroun! a pattern. then separating the %o$! into t*o ha$+es an! re%o+ing the pattern The %o$! %ust a$so contain gating an! riser s'ste% If casting is to ha+e interna$ surfaces. a core %ust #e inc$u!e! in %o$! A ne* san! %o$! %ust #e %a!e for each

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&igure 112: 3 Steps in the pro!uction se1uence in san! casting The steps inc$u!e not on$' the casting operation #ut a$so pattern3%a-ing an! %o$!3%a-ing

ISE 316 - Manufacturing

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The Pattern
A fu$$3si0e! %o!e$ of the part. s$ight$' en$arge! to account for shrin-age an! %achining a$$o*ances in the casting

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a ct u i n g

Pattern %ateria$s,

>oo! - co%%on %ateria$ #ecause it is eas' to *or-. #ut it *arps Meta$ - %ore e"pensi+e to %a-e. #ut $asts %uch $onger P$astic - co%pro%ise #et*een *oo! an! %eta$

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&igure 1123 3 T'pes of patterns use! in san! casting,

6a8

so$i! pattern

6#8 sp$it pattern 6c8 %atch3p$ate pattern 6!8 cope an! !rag pattern

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Core
&u$$3sca$e %o!e$ of interior surfaces of part

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It is inserte! into the %o$! ca+it' prior to pouring The %o$ten %eta$ f$o*s an! so$i!ifies #et*een the %o$! ca+it' an! the core to for% the casting?s e"terna$ an! interna$ surfaces Ma' re1uire supports to ho$! it in position in the %o$! ca+it' !uring pouring. ca$$e!

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&igure 112; 3 Core he$! in p$ace in the %o$! ca+it' #' chap$ets 6#8 possi#$e chap$et !esign 6c8 casting *ith interna$ ca+it'

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)esira#$e Mo$! Properties an! Characteristics

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Strength 3 to %aintain shape an! resist erosion Permeability 3 to a$$o* hot air an! gases to pass through +oi!s in san! Thermal stability 3 to resist crac-ing on contact *ith %o$ten %eta$ Collapsibility 3 a#i$it' to gi+e *a' an! a$$o* casting to shrin- *ithout crac-ing the casting

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&oun!r' San!s
Si$ica 6Si :8 or si$ica %i"e! *ith other %inera$s

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a ct u i n g

Goo! refractor' properties 3 capacit' to en!ure high te%peratures S%a$$ grain si0e 'ie$!s #etter surface finish on the cast part Large grain si0e is %ore per%ea#$e. to a$$o* escape of gases !uring pouring Irregu$ar grain shapes ten! to

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<in!ers Ase! *ith &oun!r' San!s

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San! is he$! together #' a %i"ture of *ater an! #on!ing c$a'

a ct u i n g

T'pica$ %i", B5C san!. 3C *ater. an! DC c$a'

ther #on!ing agents a$so use! in san! %o$!s,

rganic resins 6e g . pheno$ic resins8 Inorganic #in!ers 6e g . so!iu% si$icate an! phosphate8

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S E 3 1 6 -

T'pes of San! Mo$!

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Green sand molds - %i"ture of san!. c$a'. an! *aterF

a ct u i n g

GGreenH %eans %o$! contains %oisture at ti%e of pouring

!ry sand mold - organic #in!ers rather than c$a' an! %o$! is #a-e! to i%pro+e strength S"in dried mold - !r'ing %o$! ca+it' surface of a green3san! %o$! to a !epth of 15 to :7 %%. using torches or heating

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<uo'anc' in San! Casting peration

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)uring pouring. #uo'anc' of the %o$ten %eta$ ten!s to !isp$ace the core Core !isp$ace%ent can cause casting to #e !efecti+e

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&orce ten!ing to $ift core I *eight of !isp$ace! $i1ui! $ess the *eight of core itse$f
&# I >% 3 >c

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*here #b I #uo'anc' forceF $m I *eight of %o$ten %eta$ !isp$ace!F an! $c I *eight of

S E 3 1 6 -

ther E"pen!a#$e Mo$! Casting Processes

She$$ Mo$!ing Jacuu% Mo$!ing E"pan!e! Po$'st'rene Process In+est%ent Casting P$aster Mo$! an! Cera%ic Mo$! Casting

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She$$ Mo$!ing
Casting process in *hich the %o$! is a thin she$$ of san! he$! together #' ther%osetting resin #in!er

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)e+e$ope! in Ger%an' !uring ear$' 1B;5s

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&igure 1127 3 Steps in she$$3%o$!ing, 618 a %atch3p$ate or cope3an!3!rag %eta$ pattern is heate! an! p$ace! o+er a #o" containing san! %i"e! *ith ther%osetting resin

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&igure 1127 3 Steps in she$$3%o$!ing, 6:8 #o" is in+erte! so that san! an! resin fa$$ onto the hot pattern. causing a $a'er of the %i"ture to partia$$' cure on the surface to for% a har! she$$

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&igure 1127 3 Steps in she$$3%o$!ing, 638 #o" is repositione! so that $oose uncure! partic$es !rop a*a'

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&igure 1127 3 Steps in she$$3%o$!ing, 6;8 san! she$$ is heate! in o+en for se+era$ %inutes to co%p$ete curing 678 she$$ %o$! is strippe! fro% the pattern

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&igure 1127 3 Steps in she$$3%o$!ing, 668 t*o ha$+es of the she$$ %o$! are asse%#$e!. supporte! #' san! or %eta$ shot in a #o". an! pouring is acco%p$ishe! 6D8 the finishe! casting *ith sprue re%o+e!

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A!+antages an! )isa!+antages A!+antages, of She$$ Mo$!ing

a ct u i n g

S%oother ca+it' surface per%its easier f$o* of %o$ten %eta$ an! #etter surface finish on casting Goo! !i%ensiona$ accurac' Machining often not re1uire! Mo$! co$$apsi#i$it' usua$$' a+oi!s crac-s in casting Can #e %echani0e! for %ass pro!uction

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Jacuu% Mo$!ing
Ases san! %o$! he$! together #' +acuu% pressure rather than #' a che%ica$ #in!er

M a n u

a ct u i n g

The ter% H+acuu%H refers to %o$! %a-ing rather than casting operation itse$f )e+e$ope! in Kapan aroun! 1BD5

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A!+antages an! )isa!+antages of Jacuu% Mo$!ing

A!+antages,

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Eas' reco+er' of the san!. since #in!ers not use! San! !oes not re1uire %echanica$ recon!itioning nor%a$$' !one *hen #in!ers are use! Since no *ater is %i"e! *ith san!. %oisture3re$ate! !efects are a#sent

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)isa!+antages,

S E 3 1 6 -

E"pan!e! Po$'st'rene Process

Ases a %o$! of san! pac-e! aroun! a po$'st'rene foa% pattern *hich +apori0es *hen %o$ten %eta$ is poure! into %o$!

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a ct u i n g

ther na%es, lost %oam process. lost pattern process. evaporative %oam process. an! %ull mold process Po$'st'rene foa% pattern inc$u!es sprue. risers. gating s'ste%. an! interna$ cores 6if nee!e!8

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&igure 112D 3 E"pan!e! po$'st'rene casting process, 618 pattern of po$'st'rene is coate! *ith refractor' co%poun!

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&igure 112D 3 E"pan!e! po$'st'rene casting process, 6:8 foa% pattern is p$ace! in %o$! #o". an! san! is co%pacte! aroun! the pattern

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&igure 112D 3 E"pan!e! po$'st'rene casting process, 638 %o$ten %eta$ is poure! into the portion of the pattern that for%s the pouring cup an! sprue2 As the %eta$ enters the %o$!. the po$'st'rene foa% is +apori0e! ahea! of the a!+ancing $i1ui!. thus a$$o*ing the resu$ting %o$! ca+it' to #e fi$$e!2

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A!+antages an! )isa!+antages of A!+antages, Po$'st'rene Process E"pan!e!

Pattern nee! not #e re%o+e! fro% the %o$! Si%p$ifies an! e"pe!ites %o$!3%a-ing. since t*o %o$! ha$+es 6cope an! !rag8 are not re1uire! as in a con+entiona$ green3san! %o$! A ne* pattern is nee!e! for e+er' casting Econo%ic /ustification of the process is high$'

a ct u i n g

)isa!+antages,

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App$ications of E"pan!e! Po$'st'rene Process

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Mass pro!uction of castings for auto%o#i$e engines Auto%ate! an! integrate! %anufacturing s'ste%s are use! to

a ct u i n g

Mo$! the po$'st'rene foa% patterns an! then &ee! the% to the !o*nstrea% casting operation

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In+est%ent Casting 6Lost >a" Process8

A pattern %a!e of *a" is coate! *ith a refractor' %ateria$ to %a-e %o$!. after *hich *a" is %e$te! a*a' prior to pouring %o$ten %eta$

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a ct u i n g

HIn+est%entH co%es fro% one of the $ess fa%i$iar !efinitions of Hin+estH - Hto co+er co%p$ete$'.H *hich refers to coating of refractor' %ateria$ aroun! *a" pattern It is a precision casting process - capa#$e of castings of high accurac' an! intricate

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&igure 1124 3 Steps in in+est%ent casting,

618

*a" patterns are pro!uce!

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6:8 se+era$ patterns are attache! to a sprue to for% a pattern tree

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&igure 1124 3 Steps in in+est%ent casting, 638 the pattern tree is coate! *ith a thin $a'er of refractor' %ateria$ 6;8 the fu$$ %o$! is for%e! #' co+ering the coate! tree *ith sufficient refractor' %ateria$ to %a-e it rigi!

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&igure 1124 3 Steps in in+est%ent casting, 678 the %o$! is he$! in an in+erte! position an! heate! to %e$t the *a" an! per%it it to !rip out of the ca+it'

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&igure 1124 3 Steps in in+est%ent casting, 668 the %o$! is preheate! to a high te%perature. *hich ensures that a$$ conta%inants are e$i%inate! fro% the %o$!F it a$so per%its the $i1ui! %eta$ to f$o* %ore easi$' into the !etai$e! ca+it'F the %o$ten %eta$ is poure!F it so$i!ifies

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&igure 1124 3 Steps in in+est%ent casting, 6D8 the %o$! is #ro-en a*a' fro% the finishe! casting parts are separate! fro% the sprue

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A!+antages an! )isa!+antages of In+est%ent Casting

A!+antages,

M a n u

Parts of great co%p$e"it' an! intricac' can #e cast C$ose !i%ensiona$ contro$ an! goo! surface finish >a" can usua$$' #e reco+ere! for reuse A!!itiona$ %achining is not nor%a$$' re1uire! 3 this is a net shape process

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)isa!+antages

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&igure 11 B 3 A one3piece co%pressor stator *ith 154 separate airfoi$s %a!e #' in+est%ent casting 6courtes' =o*%et Corp 8

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P$aster Mo$! Casting

Si%i$ar to san! casting e"cept %o$! is %a!e of p$aster of Paris 6g'psu% 3 CaS ;3:=: 8

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a ct u i n g

In %o$!-%a-ing. p$aster an! *ater %i"ture is poure! o+er p$astic or %eta$ pattern an! a$$o*e! to set

>oo! patterns not genera$$' use! !ue to e"ten!e! contact *ith *ater

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P$aster %i"ture rea!i$' f$o*s aroun! pattern. capturing its fine !etai$s an! goo! surface finish

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A!+antages an! )isa!+antages of A!+antages, P$aster Mo$! Casting

Goo! !i%ensiona$ accurac' an! surface finish Capa#i$it' to %a-e thin cross3sections in casting Moisture in p$aster %o$! causes pro#$e%s,

a ct u i n g

)isa!+antages,

Mo$! %ust #e #a-e! to re%o+e %oisture Mo$! strength is $ost *hen is o+er-#a-e!. 'et %oisture content can cause !efects in pro!uct

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Cera%ic Mo$! Casting

Si%i$ar to p$aster %o$! casting e"cept that %o$! is %a!e of refractor' cera%ic %ateria$s that can *ithstan! higher te%peratures than p$aster

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a ct u i n g

Cera%ic %o$!ing can #e use! to cast stee$s. cast irons. an! other high3te%perature a$$o's App$ications si%i$ar to those of p$aster %o$! casting e"cept for the %eta$s cast

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Per%anent Mo$! Casting Processes

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Econo%ic !isa!+antage of e"pen!a#$e %o$! casting, a ne* %o$! is re1uire! for e+er' casting In per%anent %o$! casting. the %o$! is reuse! %an' ti%es The processes inc$u!e,

a ct u i n g

<asic per%anent %o$! casting )ie casting Centrifuga$ casting

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The <asic Per%anent Mo$! Process

Ases a %eta$ %o$! constructe! of t*o sections !esigne! for eas'. precise opening an! c$osing

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a ct u i n g

Mo$!s use! for casting $o*er %e$ting point a$$o's are co%%on$' %a!e of stee$ or cast iron Mo$!s use! for casting stee$ %ust #e %a!e of refractor' %ateria$. !ue to the +er' high pouring te%peratures

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&igure 11215 3 Steps in per%anent %o$! casting, 618 %o$! is preheate! an! coate!

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a ct u i n g

&igure 11215 3 Steps in per%anent %o$! casting, 6:8 cores 6if use!8 are inserte! an! %o$! is c$ose!

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&igure 11215 3 Steps in per%anent %o$! casting, 638 %o$ten %eta$ is poure! into the %o$!

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A!+antages an! Li%itations of Per%anent Mo$! Casting

A!+antages,

M a n u

Goo! !i%ensiona$ contro$ an! surface finish More rapi! so$i!ification cause! #' the co$! %eta$ %o$! resu$ts in a finer grain structure. so stronger castings are pro!uce! Genera$$' $i%ite! to %eta$s of $o*er %e$ting point Si%p$e part geo%etries co%pare! to san! casting #ecause of the nee! to open the %o$!

a ct u i n g

Li%itations,

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App$ications of Per%anent Mo$! Casting

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)ue to high %o$! cost. process is #est suite! to high +o$u%e pro!uction an! can #e auto%ate! accor!ing$' T'pica$ parts, auto%oti+e pistons. pu%p #o!ies. an! certain castings for aircraft an! %issi$es Meta$s co%%on$' cast, a$u%inu%. %agnesiu%. copper3#ase a$$o's. an! cast iron

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)ie Casting
A per%anent %o$! casting process in *hich %o$ten %eta$ is in/ecte! into %o$! ca+it' un!er high pressure

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a ct u i n g

Pressure is %aintaine! !uring so$i!ification. then %o$! is opene! an! part is re%o+e! Mo$!s in this casting operation are ca$$e! diesF hence the na%e !ie casting Ase of high pressure to force %eta$ into

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)ie Casting Machines

M a n u

)esigne! to ho$! an! accurate$' c$ose t*o %o$! ha$+es an! -eep the% c$ose! *hi$e $i1ui! %eta$ is force! into ca+it' T*o %ain t'pes,
12 :2

a ct u i n g

=ot3cha%#er %achine Co$!3cha%#er %achine

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S E 3 1 6 -

=ot-Cha%#er )ie Casting

Meta$ is %e$te! in a container. an! a piston in/ects $i1ui! %eta$ un!er high pressure into the !ie

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a ct u i n g

=igh pro!uction rates - 755 parts per hour not unco%%on App$ications $i%ite! to $o* %e$ting3point %eta$s that !o not che%ica$$' attacp$unger an! other %echanica$ co%ponents

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&igure 11213 3 C'c$e in hot3cha%#er casting, 618 *ith !ie c$ose! an! p$unger *ith!ra*n. %o$ten %eta$ f$o*s into the cha%#er

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&igure 11213 3 C'c$e in hot3cha%#er casting, 6:8 p$unger forces %eta$ in cha%#er to f$o* into !ie. %aintaining pressure !uring coo$ing an! so$i!ification

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Co$!3Cha%#er )ie Casting Machine

Mo$ten %eta$ is poure! into unheate! cha%#er fro% e"terna$ %e$ting container. an! a piston in/ects %eta$ un!er high pressure into !ie ca+it'

M a n u

a ct u i n g

=igh pro!uction #ut not usua$$' as fast as hot3cha%#er %achines #ecause of pouring step Casting %eta$s, a$u%inu%. #rass. an! %agnesiu% a$$o's

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a ct u i n g

&igure 1121; 3 C'c$e in co$!3cha%#er casting,

618

*ith !ie c$ose! an! ra% *ith!ra*n. %o$ten %eta$

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is poure! into the cha%#er

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&igure 1121; 3 C'c$e in co$!3cha%#er casting, 6:8 ra% forces %eta$ to f$o* into !ie. %aintaining pressure !uring coo$ing an! so$i!ification

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Mo$!s for )ie Casting

M a n u

Asua$$' %a!e of too$ stee$. %o$! stee$. or %araging stee$ Tungsten an! %o$'#!enu% 6goo! refractor' 1ua$ities8 use! to !ie cast stee$ an! cast iron E/ector pins re1uire! to re%o+e part fro% !ie *hen it opens Lu#ricants %ust #e spra'e! into ca+ities to pre+ent stic-ing

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A!+antages an! Li%itations of )ie Casting

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A!+antages,

Econo%ica$ for $arge pro!uction 1uantities Goo! !i%ensiona$ accurac' an! surface finish Thin sections are possi#$e Rapi! coo$ing pro+i!es s%a$$ grain si0e an! goo! strength to casting Genera$$' $i%ite! to %eta$s *ith $o* %eta$

a ct u i n g

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)isa!+antages,

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Centrifuga$ Casting
A group of casting processes in *hich the %o$! is rotate! at high spee! so centrifuga$ force !istri#utes %o$ten %eta$ to outer regions of !ie ca+it'

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a ct u i n g

The group inc$u!es,

True centrifuga$ casting Se%icentrifuga$ casting Centrifuge casting

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True Centrifuga$ Casting

Mo$ten %eta$ is poure! into rotating %o$! to pro!uce a tu#u$ar part

M a n u

a ct u i n g

In so%e operations. %o$! rotation co%%ences after pouring rather than #efore Parts, pipes. tu#es. #ushings. an! rings utsi!e shape of casting can #e roun!. octagona$. he"agona$. etc . #ut insi!e shape is 6theoretica$$'8 perfect$' roun!.

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a ct u i n g

&igure 11217 3 Setup for true centrifuga$ casting

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Se%icentrifuga$ Casting
Centrifuga$ force is use! to pro!uce so$i! castings rather than tu#u$ar parts

M a n u

a ct u i n g

Mo$!s are !esigne! *ith risers at center to supp$' fee! %eta$ )ensit' of %eta$ in fina$ casting is greater in outer sections than at center of rotation ften use! on parts in *hich center of casting is %achine! a*a'. thus e$i%inating the portion *here 1ua$it' is $o*est

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Centrifuge Casting

M a n u

a ct u i n g

Mo$! is !esigne! *ith part ca+ities $ocate! a*a' fro% a"is of rotation. so that %o$ten %eta$ poure! into %o$! is !istri#ute! to these ca+ities #' centrifuga$ force Ase! for s%a$$er parts Ra!ia$ s'%%etr' of part is not re1uire! as in other centrifuga$ casting %etho!s

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S E 3 1 6 -

&urnaces for Casting Processes

M a n u

&urnaces %ost co%%on$' use! in foun!ries,

Cupo$as )irect fue$3fire! furnaces Cruci#$e furnaces E$ectric3arc furnaces In!uction furnaces

a ct u i n g

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S E 3 1 6 -

Cupo$as
Jertica$ c'$in!rica$ furnace e1uippe! *ith tapping spout near #ase

M a n u

a ct u i n g

Ase! on$' for cast irons. an! a$though other furnaces are a$so use!. $argest tonnage of cast iron is %e$te! in cupo$as The Hcharge.H consisting of iron. co-e. f$u". an! possi#$e a$$o'ing e$e%ents. is $oa!e! through a charging !oor $ocate! $ess than ha$f*a' up height of cupo$a

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S E 3 1 6 -

)irect &ue$3&ire! &urnaces

S%a$$ open3hearth in *hich charge is heate! #' natura$ gas fue$ #urners $ocate! on si!e of furnace

M a n u

a ct u i n g

&urnace roof assists heating action #' ref$ecting f$a%e !o*n against charge At #otto% of hearth is a tap ho$e to re$ease %o$ten %eta$ Genera$$' use! for nonferrous %eta$s such as copper3#ase a$$o's an! a$u%inu%

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S E 3 1 6 -

Cruci#$e &urnaces
Meta$ is %e$te! *ithout !irect contact *ith #urning fue$ %i"ture

M a n u

a ct u i n g

So%eti%es ca$$e! indirect %uel %ired %urnaces Container 6cruci#$e8 is %a!e of refractor' %ateria$ or high3te%perature stee$ a$$o' Ase! for nonferrous %eta$s such as #ron0e. #rass. an! a$$o's of 0inc an! a$u%inu%

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M a n u

a ct u i n g

Figure 11.19 Three types of crucible furnaces:

(a)

liftout crucible, stationary pot, from which molten metal must be la le , an tilting!pot furnace

(b)

(c)

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S E 3 1 6 -

E$ectric3Arc &urnaces
Charge is %e$te! #' heat generate! fro% an e$ectric arc

M a n u

a ct u i n g

=igh po*er consu%ption. #ut e$ectric3arc furnaces can #e !esigne! for high %e$ting capacit' Ase! pri%ari$' for %e$ting stee$

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S E 3 1 6 -

M a n u

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Figure ".9 #lectric arc furnace for steelma$ing

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S E 3 1 6 -

In!uction &urnaces
Ases a$ternating current passing through a coi$ to !e+e$op %agnetic fie$! in %eta$

M a n u

a ct u i n g

In!uce! current causes rapi! heating an! %e$ting E$ectro%agnetic force fie$! a$so causes %i"ing action in $i1ui! %eta$ Since %eta$ !oes not contact heating e$e%ents. the en+iron%ent can #e c$ose$' contro$$e!. *hich resu$ts in %o$ten %eta$s

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M a n u

a ct u i n g

&igure 112:5 3 In!uction furnace

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La!$es

M a n u

Mo+ing %o$ten %eta$ fro% %e$ting furnace to %o$! is so%eti%es !one using cruci#$es More often. transfer is acco%p$ishe! #' ladles

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Figure 11.%1 Two common types of la les: (a) crane la le, an (b) twoman la le

S E 3 1 6 -

A!!itiona$ Steps After So$i!ification

Tri%%ing Re%o+ing the core Surface c$eaning Inspection Repair. if re1uire! =eat treat%ent

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S E 3 1 6 -

Tri%%ing
Re%o+a$ of sprues. runners. risers. parting3$ine f$ash. fins. chap$ets. an! an' other e"cess %eta$ fro% the cast part

M a n u

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&or #ritt$e casting a$$o's an! *hen cross3sections are re$ati+e$' s%a$$. appen!ages can #e #ro-en off ther*ise. ha%%ering. shearing. hac-3sa*ing. #an!3sa*ing. a#rasi+e *hee$ cutting. or +arious torch cutting %etho!s are use!

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Re%o+ing the Core

M a n u

If cores ha+e #een use!. the' %ust #e re%o+e! Most cores are #on!e!. an! the' often fa$$ out of casting as the #in!er !eteriorates In so%e cases. the' are re%o+e! #' sha-ing casting. either %anua$$' or %echanica$$' In rare cases. cores are re%o+e! #' che%ica$$' !isso$+ing #on!ing agent

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Surface C$eaning
Re%o+a$ of san! fro% casting surface an! other*ise enhancing appearance of surface

M a n u

a ct u i n g

C$eaning %etho!s, tu%#$ing. air3#$asting *ith coarse san! grit or %eta$ shot. *ire #rushing. #uffing. an! che%ica$ pic-$ing Surface c$eaning is %ost i%portant for san! casting. *hereas in %an' per%anent %o$! processes. this step can #e a+oi!e! )efects are possi#$e in casting. an!

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=eat Treat%ent

M a n u

Castings are often heat treate! to enhance properties Reasons for heat treating a casting,

a ct u i n g

&or su#se1uent processing operations such as %achining To #ring out the !esire! properties for the app$ication of the part in ser+ice

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Casting (ua$it'

M a n u

There are nu%erous opportunities for things to go *rong in a casting operation. resu$ting in 1ua$it' !efects in the pro!uct The !efects can #e c$assifie! as fo$$o*s,

a ct u i n g

)efects co%%on to a$$ casting processes )efects re$ate! to san! casting process

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Misrun A casting that has so$i!ifie! #efore co%p$ete$' fi$$ing %o$! ca+it'

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Figure 11.%% &ome common efects in castings: (a) misrun

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Co$! Shut T*o portions of %eta$ f$o* together #ut there is a $ac- of fusion !ue to pre%ature free0ing

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a ct u i n g

Figure 11.%% &ome common efects in castings: (b) col shut

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Co$! Shot Meta$ sp$atters !uring pouring an! so$i! g$o#u$es for% an! #eco%e entrappe! in casting

M a n u

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Figure 11.%% &ome common efects in castings: (c) col shot

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Shrin-age Ca+it' )epression in surface or interna$ +oi! cause! #' so$i!ification shrin-age that restricts a%ount of %o$ten %eta$ a+ai$a#$e in $ast region to free0e

M a n u

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Figure 11.%% &ome common efects in castings: ( ) shrin$age ca'ity

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San! <$o* <a$$oon3shape! gas ca+it' cause! #' re$ease of %o$! gases !uring pouring

M a n u

a ct u i n g

Figure 11.%( )ommon efects in san castings: (a) san blow

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Pin =o$es &or%ation of %an' s%a$$ gas ca+ities at or s$ight$' #e$o* surface of casting

M a n u

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Figure 11.%( )ommon efects in san castings: (b) pin holes

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Penetration >hen f$ui!it' of $i1ui! %eta$ is high. it %a' penetrate into san! %o$! or san! core. causing casting surface to consist of a %i"ture of san! grains an! %eta$

M a n u

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Figure 11.%( )ommon efects in san castings: (e) penetration

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Mo$! Shift A step in cast pro!uct at parting $ine cause! #' si!e*ise re$ati+e !isp$ace%ent of cope an! !rag

M a n u

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Figure 11.%( )ommon efects in san castings: (f) mol shift

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&oun!r' Inspection Metho!s

M a n u

Jisua$ inspection to !etect o#+ious !efects such as %isruns. co$! shuts. an! se+ere surface f$a*s )i%ensiona$ %easure%ents to insure that to$erances ha+e #een %et Meta$$urgica$. che%ica$. ph'sica$. an! other tests concerne! *ith 1ua$it' of cast %eta$

a ct u i n g

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S E 3 1 6 -

Meta$s for Casting

M a n u

Most co%%ercia$ castings are %a!e of a$$o's rather than pure %eta$s

a ct u i n g

A$$o's are genera$$' easier to cast. an! properties of pro!uct are #etter &errous Nonferrous

Casting a$$o's can #e c$assifie! as,

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&errous Casting A$$o's, Cast Iron

Most i%portant of a$$ casting a$$o's Tonnage of cast iron castings is se+era$ ti%es that of a$$ other %eta$s co%#ine! Se+era$ t'pes, 618 gra' cast iron. 6:8 no!u$ar iron. 638 *hite cast iron. 6;8 %a$$ea#$e iron. an! 678 a$$o' cast irons T'pica$ pouring te%peratures 1;55C 6:755&8. !epen!ing on co%position

M a n u

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&errous Casting A$$o's, Stee$

M a n u

The %echanica$ properties of stee$ %a-e it an attracti+e engineering %ateria$ The capa#i$it' to create co%p$e" geo%etries %a-es casting an attracti+e shaping process )ifficu$ties face! #' the foun!r' *or-ing *ith stee$,

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Pouring te%perature of stee$ is higher than for %ost other casting %eta$s 1675C 63555&8

S E 3 1 6

Nonferrous Casting A$$o's, A$u%inu%

Genera$$' consi!ere! to #e +er' casta#$e Pouring te%peratures $o* L %e$ting te%perature of a$u%inu% Tm I 665C 61::5&8 Properties,

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a ct u i n g

Light *eight Range of strength properties #' heat

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Nonferrous Casting A$$o's, Copper A$$o's

M a n u

Inc$u!es #ron0e. #rass. an! a$u%inu% #ron0e Properties,

a ct u i n g

Corrosion resistance Attracti+e appearance Goo! #earing 1ua$ities

Li%itation, high cost of copper App$ications, pipe fittings. %arine prope$$er #$a!es. pu%p co%ponents. orna%enta$

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S E 3 1 6 -

Nonferrous Casting A$$o's, Minc A$$o's

M a n u

=igh$' casta#$e. co%%on$' use! in !ie casting Lo* %e$ting point L %e$ting point of 0inc Tm I ;1BC 6D46&8 Goo! f$ui!it' for ease of casting Properties,

a ct u i n g

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Lo* creep strength. so castings cannot #e su#/ecte! to pro$onge! high stresses

S E 3 1 6 -

Pro!uct )esign Consi!erations, Geo%etric Si%p$icit'

M a n u

A$though casting can #e use! to pro!uce co%p$e" part geo%etries. si%p$if'ing the part !esign *i$$ i%pro+e casta#i$it' A+oi!ing unnecessar' co%p$e"ities,

a ct u i n g

Si%p$ifies %o$!3%a-ing Re!uces the nee! for cores I%pro+es the strength of the casting

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Pro!uct )esign Consi!erations, Corners

M a n u

a ct u i n g

Sharp corners an! ang$es shou$! #e a+oi!e!. since the' are sources of stress concentrations an! %a' cause hot tearing an! crac-s Generous fi$$ets shou$! #e !esigne! on insi!e corners an! sharp e!ges shou$! #e #$en!e!

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Pro!uct )esign Consi!erations, )raft Gui!e$ines

M a n u

In e"pen!a#$e %o$! casting. purpose of !raft is to faci$itate re%o+a$ of pattern fro% %o$! 61 for san! casting8 In per%anent %o$! casting. purpose is to ai! in re%o+a$ of the part fro% the %o$! 6: to 3 for per%anent %o$! processes8 Si%i$ar tapers shou$! #e a$$o*e! if so$i! cores are use!

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Minor changes in part !esign can re!uce nee! for coring

M a n u

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Figure 11.%* +esign change to eliminate the nee for using a core: (a) original esign, an (b) re esign

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M a n u

Pro!uct )esign Consi!erations, )i%ensiona$ To$erances an! Significant Surface !ifferences &inish in !i%ensiona$
accuracies an! finishes can #e achie+e! in castings. !epen!ing on process,

a ct u i n g

Poor !i%ensiona$ accuracies an! finish for san! casting Goo! !i%ensiona$ accuracies an! finish for !ie casting an! in+est%ent casting

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Pro!uct )esign Consi!erations, Machining A$$o*ances

M a n u

A$%ost a$$ san! castings %ust #e %achine! to achie+e the re1uire! !i%ensions an! part features A!!itiona$ %ateria$. ca$$e! the machining allo&ance. %ust #e $eft on the casting in those surfaces *here %achining is necessar' T'pica$ %achining a$$o*ances for san! castings are aroun! 127 an! 3 %% 61E16 an! 1E; in8

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