Ethiopian Technical University

Faculty of Mechanical Technology-department of Manufacturing

Technology

Advanced Metal Casting Technology (MAT515)

Open Book Test One

By: Bizuayehu Tadesse Azene

ID.No. MTR/489/13 Section 1

Submitted To Instructor: Dr. Asmamaw Tegegne (PhD)

June 2021
Addis Ababa Ethiopia
Questions

1. List down the Following Metals according To Their Cast ability And Reason out Your Answer
in Detail. Metals: stainless Steel, Zinc, High Carbon Steel, Gray Cast Iron, Brass and
Aluminum Alloys
2. Given Are Sand Casting, Centrifugal Casting, Squeeze Casting, Die Casting, Shell Casting,
Investment Casting. List Down According To Their Processing Cost, precision, Range Of
Production, Materials to Be Cast, Skill Required. Resean Out Your Answer In Detail
 1 Answer

1. Gray Cast Iron

Castings of gray cast iron have relatively few shrinkage cavities and low porosity. Various forms

of gray cast iron are ferritic, pearlitic, and martensitic. Because of differences in their structures,

each type has different properties. Typical uses of gray cast iron are in engine blocks, electromotor

housings, pipes, and wear surfaces for machines. Also, its high damping capacity has made gray

iron a common material for machine-tool bases. Gray cast irons are specified by a two-digit

ASTM designation. For example, class 20 specifies that the material must have a minimum tensile

strength of 20 ksi (140 MPa).

2. Zinc

Zinc based Alloys. A low-melting-point alloy group, zinc-based alloys have good corrosion

resistance, good fluidity, and sufficient strength for structural applications. These alloys

commonly are used in die casting, particularly for parts with thin walls and intricate shapes.

3. Aluminum alloys.

Aluminum alloys have a wide range of mechanical properties, mainly because of various

hardening mechanisms and heat treatments that can be used with them. These alloys have high

electrical conductivity and generally good atmospheric corrosion resistance. However, their

resistance to some acids and all alkalis is poor, and care must be taken to prevent galvanic

corrosion. They are nontoxic, lightweight, and have good machinability. Except for alloys with

silicon, they generally have low resistance to wear and abrasion. Aluminum-based alloys have

numerous applications, including architectural and decorative uses. An increasing trend is their use

in automobiles, for components such as engine blocks, cylinder heads, intake manifolds,

transmission cases, suspension components, wheels and brakes.

 4. Brass

Brass is an alloy of copper and zinc, in proportions which can be varied to achieve varying

mechanical, electrical, and chemical properties. ... The composition of brass, generally 66%

copper and 34% zinc, makes it a favorable substitute for copper based jewelry as it exhibits greater

resistance to corrosion.

5. High Carbon Steel

High carbon steel. Because of the high temperatures required to melt steels (up to about 1650°C,

or 3000°F), casting them requires considerable experience. The high temperatures involved

present difficulties in the selection of mold materials, particularly in view of the high reactivity of

steels with oxygen during the melting and pouring of the metal. Steel castings possess properties

that are more uniform (isotropic) than those made by mechanical working processes if welded,

need to be heat treated to restore mechanical properties. Used in equipment for railroads, mining,

chemical plants, oil fields, and heavy constructions.

6. Stainless Steel

Stainless Steels. Casting of stainless steels involves considerations similar to those for steels.
Stainless steels generally have long freezing ranges and high melting temperatures. They can
develop several structures, depending on their composition and processing parameters. Cast
stainless steels are available in various compositions, and they can be heat treated and welded.
Cast stainless-steel products have high heat and corrosion resistance, especially in the chemical
and food industries.
 Quotation 2

1. SAND CASTING
Sand casting, the most widely used casting process, utilizes expendable sand molds to form
complex metal parts that can be made of nearly any alloy. Because the sand mold must be
destroyed in order to remove the part, called the casting, sand casting typically has a low
production rate. The sand casting process involves the use of a furnace, metal, pattern, and sand
mold. The metal is melted in the furnace and then ladled and poured into the cavity of the sand
mold, which is formed by the pattern. The sand mold separates along a parting line and the
solidified casting can be removed.
The sand casting process involves the following basic steps:
 Placing a pattern (having the shape of the desired casting) in sand to make an imprint, fit in
the pattern and sand in a gating system,
 Incorporating a gating system,
 remove the pattern,
 Allowing the metal to cool until it solidifies,
 Break the sand mold and remove the casting.
 Removing the casting

Advantages:
I. Can produce very large parts
II. Can form complex shapes
III. Many material options
IV. Low tooling and equipment cost
V. Scrap can be recycled
VI. Short lead time possible
Disadvantages:
I. Poor material strength
II. High porosity possible
III. Poor surface finish and tolerance
IV. Secondary machining often required
V. Low production rate
VI. High labor cost
 Figure 1.1 Production steps in a typical sand-casting operation.

Sands
Most sand-casting operations use silica sand (SiO2) as the mold material. Sand is inexpensive and
is suitable as a mold material because of its high-temperature characteristics and high melting
point. There are two general types of sand: naturally bonded (bank sand) and synthetic (lake
sand). Because its composition can be controlled more accurately, synthetic sand is preferred by
most foundries. For proper functioning, mold sand must be clean and preferably new. Several
factors are important in the selection of sand for molds, and certain tradeoffs with respect to
properties are involved. Sand having fine, round grains can be packed closely and, thus, forms a
smooth mold surface. Although fine-grained sand enhances mold strength, the fine grains also
lower mold permeability (where fluids and gases penetrate through pores). Good permeability of
molds and cores allows gases and steam evolved during the casting to escape easily.
 2. Shell mold casting

 Shell mold casting process is recent invention in casting techniques for mass production and

smooth surface finish. It was originated in Germany during Second World War. It is also

called as Carning or C process. It consists of making a mold that possesses two or more thin

shells (shell line parts, which are moderately hard and smooth with a texture consisting of

thermosetting resin bonded sands. The shells are 0.3 to 0.6 mm thick and can be handled and

stored. Shell molds are made so that machining parts fit together-easily. They are held using

clamps or adhesive and metal is poured either in a vertical or horizontal position. They are

supported using rocks or mass of bulky permeable material. Thermosetting resin, dry powder

and sand are mixed thoroughly in a muller.

 Complete shell molding casting processes is carried in four stages. In this process a pattern is

placed on a metal plate and it is then coated with a mixture of fine sand and Phenol-resin

(20:1). The pattern is heated first and silicon grease is then sprayed on the heated metal pattern

for easy separation. The pattern is heated to 205 to 230°C and covered with resin bounded

sand. After 30 seconds, a hard layer of sand is formed over pattern. Pattern and shell are heated

and treated in an oven at 315°C for 60 sec. Phenol resin is allowed to set to a specific

thickness.

Figure 1.2 shell mold casting process

 Advantages

The main advantages of shell molding are:

 Very suitable for thin sections like petrol engine cylinder.

 Excellent surface finish.

 Good dimensional accuracy of order of 0.002 to 0.003 mm.

 Negligible machining and cleaning cost.

 Occupies less floor space.

 Skill-ness required is less.

 Molds can be stored until required.

 Better quality of casting assured.

 Mass production.

Disadvantages

 Initial cost is high.

 Specialized equipment is required.

 Resin binder is an expensive material.

 Limited for small size.

 Future of shell molding process is very bright.

Applications

 Suitable for production of casting made up of alloys of Al, Cu and ferrous metals

 Bushing

 Valves bodies

 Rocker arms

 Bearing caps

 Brackets

 Gears
 3. Investment Casting

The investment-casting process, also called the lost-wax process, was first used during the

period from 4000 to 3000 B.C. Typical parts made are components for office equipment, as well

as mechanical components such as gears, cams, valves, and ratchets. Parts up to 1.5 m (60 in.) in

diameter and weighing as much as 1140 kg (2500 lb.) have been cast successfully by this process.

The term investment derives from the fact that the pattern is invested (surrounded) with the

refractory material. Wax patterns require careful handling because they are not strong enough to

withstand the forces encountered during mold making; however, unlike plastic patterns, wax can

be recovered and reused.

The one-piece mold is dried in air and heated to a temperature of 90° to 175°C (200° to 375°F). It

is held in an inverted position for a few hours to melt out the wax. The mold is then fired to 650°

to 1050°C (1200° to 1900°F) for about four hours (depending on the metal to be cast) to drive off

the water of crystallization (chemically combined water) and to burn off any residual wax. After

the metal has been poured and has solidified, the mold is broken up and the casting is removed.
Figure 1.3 investment-casting (lost-wax) process

Advantages of investment casting:

 Parts of great complexity and intricacy can be cast

 Good surface finish and close dimensional tolerances;

 Few or no finishing operations

 Wax can usually be recovered for reuse

 Additional machining is not normally required - this is a net shape

process

 Wide variety of ferrous and nonferrous metals and alloys.

Disadvantages

 Would add significantly to the total cost of the casting, are required.

 Many processing steps are required

 Relatively expensive process

 Price per unit costs can be high

 One mold per batch

 Less strength than die cast parts

 Process is slow

 More steps are involved in production

4. CENTRIFUGAL CASTING

As its name implies, the centrifugal-casting process utilizes inertial forces (caused by
rotation) to distribute the molten metal into the mold cavities—a method that was first
suggested in the early 1800s
Types of Centrifugal casting processes
There are three types of centrifugal casting
1) True centrifugal casting
2) Semi-centrifugal casting and
3) Centrifuged casting
 True Centrifugal Casting. In true centrifugal casting, hollow cylindrical parts (such as

pipes, gun barrels, bushings, engine-cylinder liners, bearing rings with or without flanges,

and street lampposts) are produced by the technique. In this process, molten metal is

poured into a rotating mold.

 Semi centrifugal Casting. It is similar to true centrifugal casting but only with a

difference that a central core is used to form the inner surface.

This casting process is generally used for articles which are more complicated than those

possible in true centrifugal casting, but are axi-symmetric in nature.

Centrifuging. In centrifuging (also called centrifuge casting), mold cavities of any shape

are placed at a certain distance from the axis of rotation. The molten metal is poured from

the center and is forced into the mold by centrifugal forces .The properties of the castings

can vary by distance from the axis of rotation, as in true centrifugal casting.

Advantages:
 Can form very large parts
 Good mechanical properties
 Good surface finish and accuracy
 Low equipment cost
 Low labor cost
 Little scrap generated
 Disadvantages:

 Limited to cylindrical parts

 Secondary machining is often required for inner diameter
 Long lead time possible
5. Die Casting

The die-casting process, developed in the early 1900s, is a further example of permanent-

mold casting. The European term for this process is pressure die casting and should not be

confused with pressure casting. Typical parts made by die casting are housings, business-

machine and appliance components, hand-tool components, and toys.

Types of die casting machines

There are two basic types of die casting machines:

1- Hot-chamber and
2- Cold- chamber machines.

The hot-chamber process involves the use of a piston, which forces a certain volume of

metal into the die cavity through a gooseneck and nozzle. Pressures range up to 35 MPa

(5000 psi), with an average of about 15 MPa (2000 psi).

The metal is held under pressure until it solidifies in the die. To improve die life and to aid in

rapid metal cooling (thereby reducing cycle time) dies usually are cooled by circulating

water or oil through various passageways in the die block. Low-melting point alloys (such as

zinc, magnesium, tin, and lead) commonly are cast using this process. Cycle times usually

range from 200 to 300 shots (individual injections) per hour for zinc, although very small

components, such as zipper teeth, can be cast at rates of 18,000 shots per hour.

Cold-chamber process molten metal is poured into the injection cylinder (shot chamber).

The chamber is not heated—hence the term cold chamber. The metal is forced into the die

cavity at pressures usually ranging from 20 to 70 MPa (3 to 10 ksi), although they may be as

high as 150 MPa (20 ksi).

 Figure 1.4 hot-chamber die-casting process.
The machines may be horizontal or vertical, in which case the shot chamber is vertical.

High-melting-point alloys of aluminum, magnesium, and copper normally are cast using this

method, although other metals (including ferrous metals) also can be cast. Molten-metal

temperatures start at about 600°C (1150°F) for aluminum and some magnesium alloys, and

increase considerably for copper-based and iron-based alloys.

Figure, 1.5 cold- chamber die-casting process.

 Advantages

1. It is very quick process

2. It is used for mass production

3. castings produced by this process are greatly improved surface finish

4. Thin section (0.5 mm Zn, 0.8 mm Al and 0.7 mm Mg) can be easily casted

5. Good tolerances

6. Well defined and distinct surface

7. Less nos. of rejections

8. Cost of production is less

9. Process require less space

10. Very economic process

11. Life of die is long

12. All casting has same size and shape.

Disadvantages

6. Cost of die is high.

7. Only thin casting can be produced.

8. Special skill is required.

9. Unless special precautions are adopted for evaluation of air from die-cavity some air is

always entrapped in castings causing porosity.

10. It is not suitable for low production.

Applications

1. Carburetor bodies 2. Hydraulic brake cylinders 3. Refrigeration castings 4. Washing

machine 5. Connecting rods and automotive pistons 6. Oil pump bodies 7. Gears and gear

covers 8. Aircraft and missile castings, and

11. Squeeze Casting

The squeeze-casting Squeeze casting is a combination of casting and forging in which a

molten metal is poured into a preheated die, and the upper die is closed to create the mold

cavity after solidification begins. The pressure applied by the upper die in squeeze casting

causes the metal to completely fill the cavity, resulting in good surface finish and low

shrinkage

Squeeze casting can be used for both ferrous and non-ferrous alloys, but aluminum and

magnesium alloys are the most common due to their lower melting temperatures.

Automotive parts are a common application

The casting operation

The casting operation consists of preheating the die containing the preform typically to

300-400 C. The molten metal is then poured into the die and the punch is driven into the

die cavity at a constant ram speed of about 10 m/s. In most cases the optimum pressure is

20 to 30 Mp. The pressure is maintained during solidification and additional 5-10 minutes

further cooling period. The ram is then withdrawn and the composite ejected.

Two basic forms of the process may be distinguished; depending on natural the pressure is

applied.

i) the direct squeeze casting mode

ii) (ii) the indirect squeeze casting mode

 Figure 1.6 Squeeze casting Process
ADVANTAGE OF SQUEEZE CASTING

1- Better mechanical properties.

2- Fine structure minimum porosity.

3- Smooth surface.

4- High productivity.

5- Possible application in composite products.

6- Little or no machining required post casting process

LIMITATION OF SQUEEZE CASTING

2- Reduced life of the metallic mold.

3- Need to high accurately control.

4- Costs are very high due to complex tooling.

5- No flexibility as tooling

Summary of Casting Processes

Process Advantages Limitations
Sand Casting  Almost any metal can be cast; no  Some finishing required;
limit to part size, shape, or weight; relatively coarse surface finish;
low tooling cost wide tolerances
 Skill-ness required is less.
Centrifugal Casting  Large cylindrical or tubular parts  Expensive equipment; limited
with good quality; high production part shape
rate  Skilled workers are required for
operation
Squeeze Casting  Better mechanical properties.  Reduced life of the metallic
 Fine structure minimum porosity. mold.
Smooth surface.  Costs are very high due to
complex tooling.
 No flexibility as tooling
Die Casting Excellent dimensional accuracy and  High die cost; limited part size;
surface generally
finish; high production rate  limited to nonferrous metals;
long lead time
 Special skill is required.
Shell Casting Good dimensional accuracy and surface  Part size limited; expensive
finish; high production rate patterns and equipment
 Skill-ness required is less
Investment Casting Intricate part shapes; excellent surface  Part size limited; expensive
finish and accuracy; almost any metal patterns, molds, and labor
can be cast

General cost chracterctic of casting process

Process Cost Production rat

Pieces per hr.
Die Equipment Labor
Sand Casting L L L-M < 20

Centrifugal Casting M H L- M < 50

Squeeze Casting H H H

Die Casting H H L-M < 200

Shell Casting L-M M-H L-M < 50

Investment Casting M-H L-M H < 1000

L= low M= medium H =high