CASTING LAB #1 REPORT:

INTRODUCTION TO SAND CASTING PROCESSES AND METAL

CASTABILITY












Technical Report Submitted to: Dept. of Industrial & Manufacturing Engineering
Prof. Edward C. De Meter
310 Leonhard Building
The Pennsylvania State University
University Park, PA 16802




Submitted by: William Delgiorno
Erin Farrell
Joshua Kukorlo
Matt LaMarr



Date: April 2, 2014


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TABLE OF CONTENTS




INVESTIGATION RESULTS ................................................................................................................. 2

5.1 Green Sand Composition and Properties ................................................................................ 2

5.2 Green Sand Molds .................................................................................................................. 2

5.3 Cores ....................................................................................................................................... 3

5.4 Advantages and Disadvantages of EPC.................................................................................. 3

5.5 Advantages and Disadvantages of Permanent Mold Casting ................................................. 3

5.6 Advantages and Disadvantages of Investment Casting .......................................................... 4

5.7 Research on 6061 Aluminum and 356 Aluminum ................................................................. 4

5.8 Analysis of Fluidity Test Results............................................................................................ 5

REFERENCES ......................................................................................................................................... 6

APPENDIX ............................................................................................................................................. 7















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INVESTIGATION RESULTS

5.1 Green Sand Composition and Properties

Four principle components of green sand and their purposes: [1]
1. Silica Sand inexpensive and resistant to high temperatures, creates higher green strength,
more permeability, and greater refractory strength
2. Clay (Bentonite)
3. Water used to plasticize clay and enable molding
4. Combustibles ignites, resultant gases drive out moisture at the mold interface

Mullers are used to combine the sand with the additives so that the mixture is uniform. [1]

Green strength and permeability are the two most critical properties of green sand composition. A
high strength is needed to prevent mold breakage, but a strength that is too high can cause mold
interference which will cause hot tears during solidification and shrinkage. A higher permeability
allows gases to exit casting, but a lower permeability will make the surface finish better. These
properties must be controlled because an extreme of either property could ruin the mold. [2]


5.2 Green Sand Molds

Deciding how to position and orient a casting in a mold relative to the cope and drag is important.
The height of the casting should be minimalized and the largest portion kept relatively low. Also,
porosity should be taken into account. Porosity will form and float upwards due to buoyancy,
weakening parts at the top of the mold. Therefore, the more critical component of the casting should
be facing down. The location of the parting line should be flat and not contoured. Also, it is better for
the parting line to be placed on edges and corners so that the flash will not be as visible. The parting
line should be placed as low as possible relative to the casting for less-dense metals and around the
middle of the height for denser metals. [1]

A parting line is a visible line on a product that results from the sand casting process. Since the mold
is composed of two parts (cope and drag) the final product will have extra material at the line where
the cope and drag meet. [1] The typical draft relative to the parting line in sand-mold patterns ranges
from 5 to 15 mm/m, or the draft angles range from 0.5 to 2. [1]








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5.3 Cores

A core is used to create internal cavities. Cores are usually made from sand aggregates. A core print is
a recess in the mold. The core print supports the core and provides a way for gases to escape. Cores
are created in a core box, which is similar to a pattern. Sand is packed into the core box to create the
core. [1]

5.4 Advantages and Disadvantages of EPC

In comparison to green mold sand casting, what are the principal advantages and disadvantages of
EPC? In answering this question, you are going to need to go on the internet rather than rely on your
text.

Some of the principal advantages of EPC are: [3]
No cores are needed
Much more economical, and lower operating costs
Closer tolerances can be achieved
Can use regular, unclean sand, and its reusable (no additives)
Little to no cleaning

Some of the principal disadvantages of EPC are: [3]
Hard to develop the Styrofoam insert
Cant mess up. The mold and metal will be wasted


5.5 Advantages and Disadvantages of Permanent Mold Casting

In comparison to green mold sand casting, what are the principal advantages and disadvantages of
EPC? In answering this question, you are going to need to go on the internet rather than rely on your
text.

Some of the principal advantages of EPC are: [3]
No cores are needed
Much more economical, and lower operating costs
Closer tolerances can be achieved
Can use regular, unclean sand, and its reusable (no additives)
Little to no cleaning

Some of the principal disadvantages of EPC are: [3]
Hard to develop the Styrofoam insert
Cant mess up. The mold and metal will be wasted


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5.6 Advantages and Disadvantages of Investment Casting

In comparison to green mold sand casting, what are the principal advantages and disadvantages of
investment casting? Is it possible to create internal passageways using this process? If so, how is it
done?

Some of the principal advantages of investment casting are: [3]
Closer tolerances
Very fine finish
Generally good for large and small quantities of parts
Useful for alloys difficult to machine

Some of the principal disadvantages of investment casting are: [3]
Limited to smaller parts
Higher casting costs

Internal passageways are possible and are done by using internal ceramic cores that help keep the
flowing metal out so a hollow form can be made. [3]



5.7 Research on 6061 Aluminum and 356 Aluminum



Parameter Aluminum 606 Aluminum 356
Plastic Deformation or Near
Net Shape?

Ingot/Plastic Deformation Cast to near-net shape
Silicon Content (wt %) 0.4-0.8 6.5-7.5
Hardening Mechanism Precipitation Hardening Precipitation Hardening
Solidus/Liquidus (F) 1080/1205 1035/1135
Yield Strength MPa/ksi 276 /40 138/20
Ductility (% Elongation) ~(12-17) ~3






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The reason that Aluminum 356 is more castable relates directly to the aluminum-silicon phase
diagram. The transition between phases is dependent on the heat and the silicon content. For low
values of silicon, like Aluminum 6061, there is a very quick transition to the solid phase as the
temperature decreases. For Aluminum 356, the material stays in the liquid phase longer and doesnt go
directly to the solid alpha phase.



5.8 Analysis of Fluidity Test Results


Aluminum Alloy Pour Temperature
(F)
Specimen Fluidity Number
6061 1270 B 3
6061 1470 C 16
356 1200 D 10
356 1400 A 20


Liquid metal fluidity is inversely proportional to the freezing temperature range of the metal.

Freezing Range = TL TS

For 6061 aluminum, freezing range = 1205 F 1080 F = 125 F

For 356 aluminum, freezing range = 1135 F 1035 F = 100 F

Therefore, since 356 has a smaller freezing range, it has a greater fluidity as compared to 6061.

Fluidity is directly proportional to pouring temperature. Therefore, the 356 specimen with the higher
pouring temperature will have the greatest fluidity. On the other hand, the 6061 specimen with the
lower pouring temperature will have the least fluidity, which was specimen B. Specimen C was given
as being poured 200 F above its liquidus temperature, at 1470 F. Deducting 200 F from 1470 F
yields an approximate value for specimen Cs liquidus temperature, around 1270 F, which is closer to
liquidus temperature of 6061 than 356. By process of elimination, specimen D must be the 356
aluminum poured at 1200 F.






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REFERENCES


1. Kalpakjian, Serope and Steven Schmid. Manufacturing Processes for Engineering Materials.
Upper Saddle River: Prentice Hall, 2008. Print.
2. http://thelibraryofmanufacturing.com/metalcasting_sand.html
3. http://www.iron-foundry.com/green-sand-molding-vs-no-bake-sand-resin-shell-lost-wax-die-
casting-permanent-mold-centrifugal-molding.html












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APPENDIX




Table A1: Fluidity Measurements
Specimen Fluidity Number
A 20
B 3
C 16
D 10