BMCG 2323 – Manufacturing Process

Chapter 3: NET SHAPE PROCESSES -

CASTING
 Explain very well the fundamental of metal casting.
 Recognize and explain very well the type of metal casting and its equipment.

 Identify the issues arises on the aspect of manufacturing.

CONTENT
◆Introduction
◆Type of net shape processes
❖Expandable Mold
Sand Casting
Investment Casting
❖Permanent Mold
Hot and Cold Chambers Mold
Centrifugal Casting
Overview
How this engine block was made?
Engine Block
Casting Product
Engine blocks, crankshafts, automotive components, plumbing fixtures, office
equipment, etc.
 What is Metal Casting
Definition:

The casting process basically involves :

(a) pouring molten metal into a mold

patterned after the part to be
manufactured,

(b) allowing it to solidify, and

(c) removing the part from the mold.

Metal Casting
- Important considerations in casting operations are as follows:
• Flow of the molten metal into the mold cavity.
• Solidification and cooling of the metal in the mold.
• Influence of the type of mold material.

- After molten metal is poured into a mold, a series of events takes place during the
solidification of the metal and its cooling to ambient temperature.

- These events greatly influence the size, shape, uniformity, and chemical composition
of the grains formed throughout the casting, which in turn influence its overall
properties.
 Casting Design

Figure 10.8 Schematic illustration of a typical riser-gated casting. A riser, also known as a feeder, is
a reservoir built into a metal casting mold to prevent cavities due to shrinkage. Most metals are less dense as a
liquid than as a solid so castings shrink upon cooling, which can leave a void at the last point to solidify. Risers
prevent this by providing molten metal to the casting as it solidifies, so that the cavity forms in the riser and not the
casting
 Solidification: Pure Metals

Figure 10.1 (a) Temperature as a function of time for the solidification of pure metals. Note
that the freezing takes place at a constant temperature. (b) Density as a function of time
 Fluid Flow and Solidification Time
A1 h2
=
Sprue design A2 h1

vDr • Laminar < 2000

Re = •
Reynolds number h •
Mix 2000 > x > 20 000
Turbulent > 20 000

æ Volume ön
Chvorinov’s Rule Solidification time = Cç ÷
è Surface Area ø

- Two basic principles of fluid flow are relevant to gating design:

Bernoulli’s theorem and the law of mass continuity.
Bernoulli’s Theorem
This theorem is based on the principle of the conservation of
energy and relates pressure, velocity, the elevation of the
fluid at any location in the system, and the frictional losses
in a system that is full of liquid. 2
p v
h+ + = constant
Law of mass Continuity rg 2g
Any fluid moving through a pipe
obeys the Law of Continuity, which
states that the product of average
velocity (v), pipe cross-sectional
area (A), and fluid density (ρ) for a
given flow stream must remain
constant:
Q = A1v1 = A2v2
Mass continuity
FLUID FLOWS IN MOLD CASTING
- The capability of the molten
metal to fill mold cavities is
called fluidity, which consists of
two basic factors:

(1) Characteristics of the molten

metal

(2) Casting parameters.

Figure 10.9 A test method for fluidity using a
spiral mold. The fluidity index is the length of
the solidified metal in the spiral passage. The
greater the length of the solidified metal, the
greater is its fluidity.
Temperature Distribution during Metal Solidification

Figure 10.10 Temperature

distribution at the interface
of the mold wall and the
liquid metal during the
solidification of metals in
casting
 Solidified Skin on a Steel Casting

Figure 10.11 Solidified skin on a steel casting. The remaining molten metal is poured out at
the times indicated in the figure. Hollow ornamental and decorative objects are made by a
process called slush casting, which is based on this principle.
Source: After H. F. Taylor, J. Wulff, and M. C. Flemings
 Casting of an Aluminum Piston

(a) (b)

Figure 10.16 Aluminum piston for an Figure 10.17 Simulation of mold filling and
internal combustion engine: (a) as- solidification. (a) 3.7 seconds after start of
cast and (b) after machining. pouring. Note that the mushy zone has
been established before the mold is filled
completely. (b) Using a vent in the mold for
removal of entrapped air, 5 seconds after
pour.
Type of Casting
Casting Process
 METAL CASTING

TYPE OF MOLDS
i) Expandable molds ii) Permanent molds
- The mold are typically made from - Molds are made from metals which
sand, plaster, ceramic. can maintain the strength at high
- Mixed with various binders or temperature.
bonding agent in order to - The molds can be used repeatedly.
improve the properties. - Molds design – casting can be
- Sand mold: consists of 90% removed easily.
sand, 7% clay, 3% water. - Metal molds are good heat
- Mold’s materials are refractory conductors, therefore, the
type. solidification is subjected to a higher
rate of cooling.
 Type of Casting Process
Expendable Mould, Expendable Mould,
Permanent Mould
Permanent Pattern Expendable Pattern

Lost-Foam Vacuum
Sand
Process Casting

Shell Investment Slush

Mould Casting Casting

Pressure
Casting

Die Casting

Centrifugal
Casting
Summary of Casting Processes

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Characteristics of Casting
Casting Applications and Characteristics
Properties and Applications of Cast Irons
Mechanical Properties of Gray Cast Irons
Cost Characteristics of Casting
 Sand Casting
Expendable Mold, Expendable Mold,
Permanent Mold
Permanent Pattern Expendable Pattern

Sand Lost-Foam Vacuum

Casting Process Casting

Shell Investment Slush

Molding Casting Casting

Pressure
Casting

Die Casting

Centrifugal
Casting
 Introduction
• Sand casting, the most widely • The sand casting process
used casting process, utilizes involves the use of a furnace,
expendable sand molds to form metal, pattern, and sand mold.
complex metal parts that can be • The metal is melted in the
furnace and then ladled and
made of nearly any alloy. poured into the cavity of the
• Because the sand mold must be sand mold, which is formed by
destroyed in order to remove the the pattern.
part, sand casting typically has a • The sand mold separates along a
parting line and the solidified
low production rate. casting can be removed.
 CASTABILITY OF METAL
GOOD FEASIBLE
• Alloy Steel • Lead
• Carbon Steel • Tin
• Cast Iron • Titanium
• Stainless Steel • Zinc
• Aluminum
• Copper
• Magnesium
• Nickel
Schematic illustration of a sand mold.
Factors to be considered in selecting of sand for molds:
Type of Sand Molds: •Sand with fine, round grains can be packed
closely – forms a smooth mold surface
1. Green Sand •Fine-grained sand enhances the mold strength
and lower mold permeability
2. Cold-Box
3. No-Bake
•Good permeability of molds and cores allows
gases and steam evolved during the casting to
escape easily.
•The mold should also have good collapsibility
to allow for the casting to shrink while cooling –
to avoid defects in casting such as hot tearing
and cracking.
Sand Casting - Green sand

❑ The most common used as molds

❑ Mixture of sand, clay and water.
❑ Least expensive in making molds
❑ Sand is recycled easily for subsequent use
❑ Commonly used in the casting of non-
ferrous alloys, which include aluminum
and brass.

The term "green sand" is known, principally

because of the moisture content within the sand.
Sand Casting – Cold Box

❑ Various organic and inorganic binders are

blended into the sand to bond the grains
and the mixture hardens at room
temperature
❑ Chemically for greater strength.
❑ This kind of molds are more accurate
dimensionally than green-sand molds
Binder for Cold Box
Sand Casting - No- ❑ No-bake, or "Dry sand", molding uses
Bake chemically bonded sand and is usually
used for castings requiring intricate
detail.

❑ - Synthetic liquid resin is mixed with the

sand – the mixture hardens at room
temperature.

❑ Dry sand allows us to create a casting

with high mechanical properties and
dimensional stability.

❑ Complex core packages may be set into

the molds to create intricate parts with
stable wall thickness.
 Shell Moulding
Casting
Expendable Mold, Expendable Mold,
Permanent Mold
Permanent Pattern Expendable Pattern

Sand Lost-Foam Vacuum

Casting Process Casting

Shell Investment Slush

Molding Casting Casting

Pressure
Casting

Die Casting

Centrifugal
Casting
Shell Moulding Casting
❑ Good dimensional accuracy
❑ Better surface finish
 Lost-Foam (Evaporative)
Casting
Expendable Mold, Expendable Mold,
Permanent Mold
Permanent Pattern Expendable Pattern

Sand Lost-Foam Vacuum

Casting Process Casting

Shell Investment Slush

Molding Casting Casting

Pressure
Casting

Die Casting

Centrifugal
Casting
 LOST FOAM CASTING
❑ Uses a mold of sand packed around a
polystyrene foam pattern which vaporizes
when molten metal is poured into mold

❑ Other names: lost-foam process, lost pattern

process, evaporative-foam process, and full-
mold process

❑ Polystyrene foam pattern includes sprue,

risers, gating system, and internal cores (if
needed)

❑ Mold does not have to be opened into cope

and drag sections
Lost Foam/Evaporative Casting Process

Figure 11.11 Schematic illustration of the expandable-pattern casting process, also

known as lost-foam or evaporative casting.
 Investment
Casting
Expendable Mold, Expendable Mold,
Permanent Mold
Permanent Pattern Expendable Pattern

Sand Lost-Foam Vacuum

Casting Process Casting

Shell Investment Slush

Molding Casting Casting

Pressure
Casting

Die Casting

Centrifugal
Casting
 INVESTMENT CASTING
INVESTMENT CASTING

EXPANDABLE MOLD
Also known as lost-wax process.

Part’s dimension: up to 1.5m in diameter, 1140kg in

weight.

Investment casting derives from the pattern being

invested (surrounded) with a refractory material. Many
materials are suitable for investment casting; stainless
steel alloys, brass, aluminum, carbon steel and glass.

The material is poured into a cavity in a refractory

material that is an exact duplicate of the desired part.
Due to the hardness of refractory materials used,
investment casting can produce products with
exceptional surface qualities, which can reduce the need
for secondary machine processes.
Why Investment Casting?
Design flexibility
Investment casting produces near-net-shape configurations, offering designers and engineer’s freedom of
design in a wide range of alloys. The process is capable of producing precise detail and dimensional
accuracy in parts weighing few grams to many kilograms.

Wide range of alloys

Many ferrous and non-ferrous alloys can be routinely casted

Reduction of production costs

Costly machining operations are reduced and often eliminated. No capital equipment investment is
needed to produce parts in-house.

Reduction of assembly operations

Several parts can be made as one casting, reducing handling, assembly and inspection costs.

Reproduction of fine details

Splines, holes, bosses, lettering, serrations and even some threads can be cast.

Consistency of Components
Since cast components are produced by using wax patterns from a single tool, dimensional accuracy is
the same from part to part, year after year. When design changes are required, it is usually possible to
alter existing tooling at a relatively minor cost.
Investment Casting Process

Figure 11.13 Schematic illustration of investment casting (lost-wax) process. Castings by this
method can be made with very fine detail and from a variety of metals. Source: Courtesy of
Steel Founder’s Society of America.
❑ Patterns are made
from wax or plastic,
e.g. polystyrene. The
wax can be recovered
and reused.

❑ The pattern can be

produced by
machining process or
rapid prototyping.
 Hardening allows coatings to
cure. These steps are repeated
until the investment reaches its
required thickness—usually 5 to
15 mm (0.2 to 0.6 in)

i. Slurry Coating– ii. Stucco coating or render -Once when the coating is
the tree is merge into a slurry is a material made of dried and solidified, the
of refractory material and aggregates, a binder, and pattern will keep continue
then draining to create a water (coarse ceramic with the coating process to
uniform surface coating (to particles) increase the thickness and
preserve fine details from the the strength.
mould. ) White Fused Alumina,
White Fused Mullite and
silica and binders including Andalusite
water, ethyl silicate, and acids)
❑ The complete mold is dried
in air and than heated with
temperature of 900C to
1750C.

❑ This process will take place

until 12 hours in order to
melt out the wax.

❑ Again, the mold will be

heated to 6500C to 10500C
in 4 hours to eliminate the
water of crystallization
(chemical combined with
water) and residual wax if
any
❑Once when the molten has been
poured into the mold and has
solidified, the mold is broken up and
the casting now can be removed.
https://www.youtube.com/watch?v=WXFRRg8YMT0