Mr. D.A.

Ghatge

INTRODUCTION

Foundry Engineering deals with the process of making casting in moulds prepared by patterns Stages:
1. 2. 3. 4. 5.

Pattern making Moulding and core making Melting and casting Fettling Testing and inspection

FOUNDRY HAND TOOLS

FOUNDRY HAND TOOLS

FOUNDRY HAND TOOLS

FOUNDRY HAND TOOLS

FOUNDRY HAND TOOLS - LADLES

FOUNDRY HAND TOOLS- CRUCIBLES

MELTING EQUIPMENTS
In order to obtain the proper pouring and melting temperature of the metal several furnaces are used: For ferrous metals:

Cupola furnaces Open heart furnaces Electric furnaces

For non-ferrous metals:

Pit Type Stationary type Tilting Type

CUPOLA
Used for melting for cast iron. Low cost. Better control of temp and chemical composition. Easy tapping. Consumes easily available fuels.

ELECTRIC FURNACE
High

Temp. Fast Melting. Controlled atm. For large quantities. High cost and maintenance. Fumes, smoke and noise.

OIL / GAS FIRED ROTARY FURNACE

MOULDING
Mould

is a void or cavity created in a compact sand mass with the help of pattern. Core is a sand shape exactly similar to the cavities to be produced in casting. Generally made differently in a core box. Permanent moulds are made up of ferrous metals and alloys, normally used for casting of low melting point material, costly Temporary refractory moulds are made of refractory sands and resin, for high melting points and bigger objects, Cheap.

PATTERNS
AND CORES

Pattern

Mould

Core

Mould Hole in Job by Core

Casted Job Casted Job

MAIN CONSTITUENTS OF MOULDING

SAND
Principle Constituents: Silica Sand

Major Portion, 80-82 % High Softening Temperature and thermal Stability, chemical resistively and permeability. Found in banks and bottom of rivers.
Imparts sufficient strength and cohesiveness, but decreases permeability of sand. Organic, in-organic and Clay are used.

Binders

Additives Water

ADDITIVES OF MOULDING SAND

ADDITIVES OF MOULDING SAND

SAND GRAINS

PROPERTIES OF MOULDING SAND

Porosity

or Permeability Flowability or Plasticity Refractoriness Adhesiveness Cohesiveness Collapsibility Durability Fitness Bench life Co-efficient of expansion Chemically Neutral Reusable, Cheap and Easily available

CLASSIFICATION OF MOULDING SAND

SPECIAL SAND

SPECIAL SAND

SPECIAL SAND

PREPARATION MOULDING SAND

SAND TESTING

MOULDING PROCESS
According to the method Used: 1. Floor Moulding Foundry floor acts as drag and may be covered with cope or may be casted open. Used for all medium and large casting 2. Bench Moulding For small and light moulds Done in cope and drag 3. Pit Moulding Moulding for extremely large casting is done in pit Pit acts as drag and separate cope can be used to make gates and runners

MOULDING PROCESS
4. Machine Moulding All the jobs of ramming, moulding and gate making, drawing of pattern is done by machines. Produces identical and consistent castings Preferred for the mass production

MOULDING PROCESS

MOULDING PROCESS

MOULDING PROCESS

MOULDING PROCESS

GATING SYSTEM
Gating

System means all the passages through which the molten metal enters the mould cavity. Includes:
Pouring basin Runner Gate Riser

It

has great impact upon the quality of the casting produced.

REQUIREMENT OF GATING SYSTEM

Low flow velocity of molten metal. Insure complete filling of cavity. Prevent absorption of moisture while flow. Prevent formation of oxides. Prevent entry of slag, dross etc. Assist directional solidification. Should be practical and economical.

TYPES OF GATES
1. 2.

3.
4.

Top Gate Bottom Gate Parting Gate Step Gate

TYPES OF GATES

SPECIAL CASTING PROCESSES

GRAVITY DIE OR PERMANENT MOULD CASTING

Molten metal is poured under gravity only. Uses permanent moulds; can be reused many times Made of grey cast iron; inner surface coated with refractories. Made in two halves with built-in gating system.

CENTRIFUGAL CASTING
Mould

is rotated rapidly about its central axis as the metal is pored into it. Centrifugal force plays major role in shaping and feeding of the casting. C.F. helps to distribute the molten metal evenly to all surfaces and separates the slag from out flowing molten metal. Three types:
1. True Centrifugal 2. Semi Centrifugal 3. Centrifuge

TRUE CENTRIFUGAL CASTING

TRUE CENTRIFUGAL CASTING

SEMI CENTRIFUGAL AND CENTRIFUGE CASTING

CARBON DIOXIDE MOULDING

This

process is basically a hardening process for the moulds and cores. As Co2 gas is passed through a sand mixture containing sodium silicate, the sand immediately becomes extremely strong bonded as sodium silicate becomes a stiff gel giving the necessary strength to the mould. Pure dry silica is mixed with 3-5% sodium silicate and water; and is rammed in the moulding box. Co2 is forced into mould at high pressure. Additional hardening may be done by baking.

CARBON DIOXIDE MOULDING

CARBON DIOXIDE MOULDING

SHELL MOULDING
The sand mixed with thermosetting resign is allowed to come into contact with heated metallic pattern plate. A thin and strong shell of mould is formed around the pattern. The shell is removed from the pattern and paced in cope and drag with backing material and molten metal is poured for casting.

SHELL MOLDING PROCESS

It

is a process in which, the sand mixed with a thermosetting resin is allowed to come in contact with a heated pattern plate (200 oC), this causes a skin (Shell) of about 3.5 mm of sand/plastic mixture to adhere to the pattern.. Then the shell is removed from the pattern. The cope and drag shells are kept in a flask with necessary backup material and the molten metal is poured into the mold.

SHELL MOLDING PROCESS

This

process can produce complex parts with good surface finish 1.25 m to 3.75 m, and dimensional tolerance of 0.5 %. A good surface finish and good size tolerance reduce the need for machining. The process overall is quite cost effective due to reduced machining and cleanup costs. The materials that can be used with this process are cast irons, and aluminum and copper alloys.

SHELL MOLDING PROCESS

MOLDING SAND IN SHELL MOLDING PROCESS

The molding sand is a mixture of fine grained quartz sand and powdered Bakelite. There are two methods of coating the sand grains with Bakelite. First method is Cold coating method and another one is the hot method of coating.

COLD COATING,
In

the method of cold coating,

quartz sand is poured into the mixer and then the solution of powdered bakelite in acetone and ethyl aldehyde are added. The typical mixture is 92% quartz sand, 5% bakelite, 3% ethyl aldehyde. During mixing of the ingredients, the resin envelops the sand grains and the solvent evaporates, leaving a thin film that uniformly coats the surface of sand grains, thereby imparting fluidity to the sand mixtures.

HOT COATING.
In

the method of hot coating,

the mixture is heated to 150-180 o C prior to loading the sand. In the course of sand mixing, the soluble phenol formaldehyde resin is added. The mixer is allowed to cool up to 80 90 o C. This method gives better properties to the mixtures than cold method.

SHELL MOULDING

Shell For Moulding

Rotational Shell Moulding

SHELL MOULDING

INVESTMENT CASTING
-The basic steps of the investment casting process are Production of heat-disposable wax, plastic, or polystyrene patterns Assembly of these patterns onto a gating system ?Investing,? or covering the pattern assembly with refractory slurry Melting the pattern assembly to remove the pattern material Firing the mold to remove the last traces of the pattern material Pouring Knockout, cutoff and finishing.

INVESTMENT CASTING

The investment casting process also called lost wax process begins with the production of wax replicas or patterns of the desired shape of the castings. A pattern is needed for every casting to be produced. The patterns are prepared by injecting wax or polystyrene in a metal dies. A number of patterns are attached to a central wax sprue to form a assembly. The mold is prepared by surrounding the pattern with refractory slurry that can set at room temperature. The mold is then heated so that pattern melts and flows out, leaving a clean cavity behind. The mould is further hardened by heating and the molten metal is poured while it is still hot. When the casting is solidified, the mold is broken and the casting taken out.

INVESTMENT CASTING
Steps in the investment casting process
(a) Wax patterns are produced by injection molding

(b) Multiple patterns are assembled to a central wax sprue

(c) A shell is built by immersing the assembly in a liquid ceramic slurry and then into a bed of extremely fine sand. Several layers may be required.

(d) The ceramic is dried; the wax is melted out; ceramic is fired to burn all wax.

wax(e) The shell is filled with molten metal by gravity pouring. On solidification, the parts, gates, sprueand pouring cup become one solid casting. Hollow casting can be made by pouring out excess metal before it solidifies.

(f) After metal solidifies, the ceramic shell is broken off by vibration or water blasting

(g) The parts are cut away from the sprue using a high speed friction saw. Minor finishing gives final part.

Continuous casting is a casting method, in which the steps of pouring, solidification and withdrawal (extraction) of the casting from an open end mold are carried out continuously. Cross-sectional dimensions of a continuous casting are constant along the casting length and they are determined only by the dimensions of the mold cavity. The length of a continuous casting is limited by the life time of the mold. Continuous casting technology is used for both ferrous and non-ferrous alloys.

Traditional continuous casting processes use stationary (or oscillating) molds, in which the solidified bar moves relative to the mold surface. Friction caused by the movement results in formation of micro-cracks and other defects in the surface regions of the casting.

Lubricating oil supplied to the mold surface and selflubricating graphite molds decrease the friction/sticking and reduce the defective surface zone. This defective zone is commonly machined (milled) prior to Rolling The alternative continuous casting methods use moving endless molds (rolls, belts, wheels) characterized by zero relative movement between the mold and casting surfaces. Strips and slabs fabricated by Continuous casting in traveling mold have low defect surface. The castings may be further processed (rolled) without surface machining.

Depending on the mold position (vertical or horizontal) continuous casting machines may be vertical horizontal.

VERTICAL CONTINUOUS CASTING

Steels are commonly cast in vertical continuous casting machines Molten metal is continuously supplied from the ladle to the intermediate ladle (tundish) from which it is continuously poured into the mold at a controllable rate keeping the melt level at a constant position.

The water-cooled copper mold (primary cooling zone) extracts the heat of the metal causing its solidification. The mold oscillates in order to prevent sticking with the casting.

VERTICAL CONTINUOUS CASTING

When the casting goes out from the mold it is cooled in the secondary cooling zone by water (or water with air) sprayed on the casting surface. Most of vertical continuous casting machines are equipped with strand guide units bending the casting and changing its configuration from vertical to horizontal.

The casting is continuously extracted from the mold by the withdrawal unit followed by a cut-off unit.

VERTICAL CONTINUOUS CASTING

The casting process begins from inserting a dummy (primary) bar into the mold. Then a molten metal is poured into the mold where it solidifies and grips the end of the dummy bar. The dummy bar is disconnected from the casting after passing the withdrawal unit.

HORIZONTAL CONTINUOUS CASTING

Horizontal continuous casting machine is generally used for casting nonferrous alloys. Horizontal continuous casting in stationary mold with graphite water-cooled molds, Twin-roll caster and Twin-belt caster are most popular methods of this type. Due to the water cooling (primary and secondary) solidification rate provided by continuous casting is higher than in other casting methods therefore continuous castings have more uniform and finer grain structure and enhanced mechanical properties.

CASTING DEFECTS

CASTING DEFECTS
1. 2. 3. 4. 5. 6. 7. 8. 9.

10.
11. 12.

Blow holes Porosity Shrinkage Hot tears Drop Metal Penetration Fusion Shot metal Shift Swells Hard Spots Warpage

CASTING DEFECTS

CASTING DEFECTS

CASTING DEFECTS

CASTING DEFECTS

CASTING DEFECTS

CASTING DEFECTS

CLEANING OF CASTING (FETTLING)

After casting has solidified it is removed form the mould and is cleaned to remove the runner risers cores etc. Rough Cleaning Surface cleaning

1. 2.

Wire brush Sand blasting Shot Blasting

3.
4.

Finishing Inspection of casting

Destructive and Non-Destructive

INSPECTION OF CASTING
Destructive Cutting samples and examining properties Tensile, Compression and Torsion Testing Non-Destructive Visual Inspection Dimensional Inspection Pressure Testing Radiographic Inspection Magnetic Inspection

THE END
Self Reading assignment: Chills and Chaplets Continuous Casting Investment casting and Injection casting