Metal casting

Casting is a manufacturing process whereby the desired material is heated to the liquid state,
then introduced into a previously prepared mold cavity of proper design, and allowed to
solidify

Advantages of Casting

Low cost and quick

Easier to manufacture

Can produce intricate shapes and internal openings

Can produce parts in one piece

Best suited for composite components

When are Metal Castings required

To allow the shaping of difficult materials

To produce certain material properties

To produce efficient stress distributions

To produce very complex shapes with internal cavities or hollow sections

To produce very large parts ( 1 oz to 200 tons )

To produce work-piece materials that are difficult or uneconomical to process by other

means

casting is competitive with other processes.

Factors that affect the overall properties of the cast part

Type of metal

Thermal properties of the metal

Thermal properties of the mold

Geometric relationship between volume and surface area of the casting

Shape of the mold

 Porosity of the mold

Metal pour rate

The important considerations in casting process

Flow of Molten Metal

Solidification and Cooling

Type of Mold Material

Sprue is a vertical channel though which the molten metal flows downward in the mold

Runners channels that carry the molten metal from the sprue to the mold cavity

Gate is the portion of the runner though which the molten metal enters the mold cavity

Risers serve as reservoirs to supply the molten metal necessary to prevent shrinkage

Techniques for minimizing turbulence

Avoid sudden changes in flow direction

Dross or slag can be eliminated by vacuum casting

Use of filters eliminates turbulent flow in the runner system

Types of casting
 Expendable molds- molds made of sand, plaster, ceramics, or other materials
capable of withstanding high temperatures which are broken up and discarded
after a single use.

Permanent Molds- molds usually made of metal which maintain strength at high
temperatures and are used for making a large number of repeated castings.

Composite Molds- molds which use elements of both expendable and

permanent molds.

Core

Cores are typically used for more complex shapes

Cores allow features that could not be easily formed into a sand core.

Cores are made with techniques similar to those for making sand molds.

The cores may need structural support in the mold - these metal supports are called
chaplets.

The cores are added when the cavity are made, and they act as part of the mold during
casting, but they are rigid enough to allow internal features on parts.

Factors Induced defect in casting

Unsuitable or unsatisfactory raw material used in molding, core making or casting

The application of unsatisfactory molding or casting practice by the individual worker or

incorrect advise by the supervisor

The use of improper tools, equipment, appliances, or pattern

Un professional management policies relating to the fixing of incentive plans and setting
up of production procedure, faulty organization and poor work discipline, or lack of
training.

Capabilities and Advantages of Casting

Can create complex part geometries

Can create both external and internal shapes

Some casting processes are net shape; others are near net shape
 Can produce very large parts

Some casting methods are suited to mass production

Disadvantages of Casting

Limitations on mechanical properties

Poor dimensional accuracy and surface finish for some processes; e.g., sand
casting

Safety hazards to workers due to hot molten metals

Environmental problems

Directional Solidification

To minimize damaging effects of shrinkage, it is desirable for regions of the casting most
distant from the liquid metal supply to freeze first and for solidification to progress from
these remote regions toward the riser(s)

Thus, molten metal is continually available from risers to prevent shrinkage voids

The term directional solidification describes this aspect of freezing and methods
by which it is controlled