MDP 251

Casting and Welding 1

LAB 1

Name: Omar Alaa Eldin Mohamed 18P9390

Seif Khaled seif Elmolook 21P0143
May Fadl Helil 18P8064

Submitted to: DR. Ramadan

Eng. Bassem
Table of Contents
CASTING ...................................................................................................................................... 4
1.1 INTRODUCTION .......................................................................................................................... 4

2. SAND CASTING..................................................................................................................... 4
2.1 INTRODUCTION .......................................................................................................................... 4
2.2 WORKING PROCESS .................................................................................................................... 4
THIS PROCEDURE NECESSITATES THE FOLLOWING STEPS: ................................................................................ 4
 TO MAKE A MOLD, CREATE A PATTERN IN SAND.................................................................................... 4
 TAKE OUT THE PATTERN. .................................................................................................................. 4
 FILL THE MOLD CAVITY WITH MOLTEN METAL. ..................................................................................... 4
 ALLOW THE METAL TO SOLIDIFY BY COOLING IT. ................................................................................... 4
 REMOVE THE CASTING PRODUCT ...................................................................................................... 4
AND BREAK AWAY THE SAND ..................................................................................................................... 4
MOLD. ................................................................................................................................................... 4
2.3 EQUIPMENT .............................................................................................................................. 5
THE FOLLOWING ITEMS ARE REQUIRED FOR SAND CASTING: ............................................................................ 5
2.3.1. Pattern.................................................................................................................................. 5
2.3.2. Core ...................................................................................................................................... 5
2.2.3. Riser ...................................................................................................................................... 5
2.3.4. Gates .................................................................................................................................... 5
2.3.5. Runner .................................................................................................................................. 5
2.3.6. Molding box.......................................................................................................................... 6
2.4 SAND MOLD.............................................................................................................................. 6
2.4.1. Green Sand mold .................................................................................................................. 6
2.4.2. Dry sand mold...................................................................................................................... 6
2.5 PROPERTIES OF SAND .................................................................................................................. 6
2.5.1 Adhesiveness ................................................................................................................... 6
2.5.2 Cohesiveness ..................................................................................................................... 7
2.6 LIMITATIONS OF SAND CASTING .................................................................................................. 7
2.7 PRODUCTS FORMED BY SAND CASTING ........................................................................................ 7
3. HAND TOOLS: ...................................................................................................................... 7
3.1 RAMMER................................................................................................................................ 7
3.2 SHOVEL .................................................................................................................................... 8
3.3 HAND RIDDLE .......................................................................................................................... 8
3.4 STRIKE OFF BAR ......................................................................................................................... 8
3.5 VENT WIRE ............................................................................................................................... 8
3.6 L MALLET .................................................................................................................................. 8
............................................................................................................................................................ 8
3.7 SPOONS AND SLICKS.................................................................................................................... 8
3.8 CLAMPS: ................................................................................................................................. 9
3.9 BELLOW ................................................................................................................................... 9
HELP BLOW ANY SAND FROM SURFACE OF MOLD CAVITY ................................................................................ 9
3.10 DRAW SPIKE: ........................................................................................................................... 9
3.11 DRAW SCREWS .......................................................................................................................... 9
4. STEPS OF PREPARING THE MOLD .......................................................................................... 9
5. DIFFERENCE BETWEEN SAND AND DIE CASTING .................................................................. 16
FIGURE 1 CASTING MOLD .............................................................................................................................................. 4
FIGURE 2 WORKING STEPS ............................................................................................................................................ 4
FIGURE 3 PATTERN....................................................................................................................................................... 5
FIGURE 4 CORE BOX ..................................................................................................................................................... 5
FIGURE 5 SPRUE AND RISER............................................................................................................................................ 5
FIGURE 3 MOLDING BOX ............................................................................................................................................... 6
FIGURE 4 RAMMER ...................................................................................................................................................... 7
FIGURE 5 SHOVEL ........................................................................................................................................................ 8
FIGURE 6 RIDDLE ......................................................................................................................................................... 8
FIGURE 7 STRIKE OFF BAR .............................................................................................................................................. 8
FIGURE 11 L MALLET .................................................................................................................................................... 8
FIGURE 8 VENT WIRE.................................................................................................................................................... 8
FIGURE 13 SPOON ....................................................................................................................................................... 8
FIGURE 14 BELLOW ...................................................................................................................................................... 9
FIGURE 15 DRAW SCREW .............................................................................................................................................. 9
FIGURE 16 FIX UPPER PATTERN ..................................................................................................................................... 10
FIGURE 17 PUT SPRUE, RISER AND COPE FLASK................................................................................................................. 10
FIGURE 18 AFTER COPE SURFACE LEVELING ..................................................................................................................... 11
FIGURE 19 OPENED MOLD ........................................................................................................................................... 11
FIGURE 20 DRAG AFTER REMOVING PATTERN .................................................................................................................. 12
FIGURE 21 COPE AFTER REMOVING PATTERN................................................................................................................... 12
FIGURE 22 RUNNER ................................................................................................................................................... 12
FIGURE 23 CORE MOLD ............................................................................................................................................... 13
FIGURE 24 FINAL CORE SHAPE ...................................................................................................................................... 13
FIGURE 25 FINAL ASSEMBLY ......................................................................................................................................... 14
FIGURE 26 POURING MOLTEN METAL ............................................................................................................................ 14
FIGURE 27 WAITING FOR COOLING ................................................................................................................................ 15
FIGURE 28 FINAL PRODUCT FOR SAND CASTING................................................................................................................ 15
FIGURE 29 FINAL PRODUCT FOR DIE CASTING................................................................................................................... 16
 Casting
1.1 introduction
Casting manufacturing process is melting metal or any molten material is poured into a
mold cavity to get a desired shape of product then passing through solidification. After total
solidification product is extracted from mold.
The following figure give a brief explanation of mold parts:

Figure 1 casting mold

2. Sand casting
2.1 Introduction
It is a relatively popular sort of casting. The casting mold in this procedure is constructed of
relatively inexpensive sand that is adequately refractory even for steel foundry use. A design
is used to build the cavity in the sand mold.

2.2 Working process

This procedure necessitates the following steps:

 To make a mold, create a pattern in sand.
 Take out the pattern.
 Fill the mold cavity with molten metal.
 Allow the metal to solidify by cooling it.
 Remove the casting product Figure 2 Working Steps
and break away the sand
mold.
 2.3 Equipment
The following items are required for sand casting:
1. Pattern

2. Core

3. Riser

4. Gates

5. Runner

6. Molding box

2.3.1. Pattern
pattern is a prototype of a product that is used to make the cavity in
the sand flask giving the required dimensions and shape of wanted
casting product. where upper part of flask is cope while lower part
called drag.
Figure 3 pattern

2.3.2. Core
Used for internal cavities of a product

2.2.3. Riser
It is used as a reservoir for supplying material to the casted product overcoming
Figure 4 core box
solidification allowances, indicator that the hole
product is filled and a vent for air leakage.
2.3.4. Gates
allow metal to flow from runner to the product.

2.3.5. Runner Figure 5 sprue and riser

It is responsible for the flow of molten metal from sprue to gates and supply a uniform
flowrate of molten metal to gates as required.
 2.3.6. Molding box
it is known as flask, holding all required components for the casting process. It is divided to
two parts, upper part called cope, while lower part called drag, where they are separated by
parting line.
2.4 Sand Mold
Sand Molds Several kinds of molds are utilized in the casting process; a few of them are
listed below.

2.4.1. Green Sand mold

Sand casting use sand molds made from wet sand that contains water and organic bonding
components known as clay. This sand is known as green sand because the sand mold is not
set and remains green or uncured long after the metal is poured into it.

Figure 6 Molding box

2.4.2. Dry sand mold

An improved version of the green sand procedure called "dry sand casting" involves heating
the sand mold at 300 degrees Fahrenheit in order to eliminate moisture and strengthen it. It
makes it more collapsible. Because the procedure is difficult to use, it is not very frequent.

2.5 properties of sand

Adhesiveness Cohesiveness Collapsibility Permeability Refractoriness

2.5.1 Adhesiveness
Adhesiveness is a feature of molding sand that allows it to attach or stick to other materials,
such as the inside wall of a molding box.
 2.5.2 Cohesiveness

The ability of the molding sand's grain particles to interact and attraction to one another is
known as cohesiveness. Sand needs to be cohesive enough to provide sand mold sufficient
strength. To boost cohesion, materials like as clay, olivine, and zinc are added.

2.6 Limitations of sand casting

 There are restrictions on the casting products' size and weight.
 Lower material strength than a machined item because to significant porosity.
 The wall surface texture's internal sand mold is the cause of the poor surface finish.
flaws or variations in quality, such as porosity, pouring metal flaws, surface defects,
and shrinkage, are common in metallurgical processes.

2.7 Products Formed by Sand Casting

 Small engine parts
 Gears
 Bearings
 Nuts
 Pumps
 pulleys

3. HAND TOOLS:
3.1 RAMMER
After covering pattern with sand a rammer is used to
ensure that all the surrounding cavity of pattern is filled
with sand by ramming it.

Figure 7 rammer
 3.2 Shovel
It is made up of a wooden handle attached to an iron
pan. It is employed in the manual conditioning and
mixing of foundry sand before to its transfer to the flask.

Figure 8 Shovel
3.3 Hand Riddle
It used to filter the sand from any foreign material

Figure 9 Riddle
3.4 Strike Off Bar
It is used for removing excess sand above the mold after
ramming it creating a flat surface.

Figure 10 Strike off bar

3.5 Vent Wire

After the mold is rammed and stroked off vents are
made using vent wire. To help gasses escape.

Figure 12 Vent wire

3.6 L mallet

Used for filling sharp and rounded edges by

ramming the sand as it fits in small areas

Figure 11 l mallet

3.7 Spoons and slicks

Finishing and removing excess sand from

cope and drag and used for creating pouring
cup.
Figure 13 spoon
 3.8 Clamps:
Help holding cope and drag together

3.9 Bellow
Help blow any sand from surface of mold cavity

Figure 14 bellow

3.10 Draw Spike:

Used for expanding pattern cavity to draw pattern from mold

3.11 Draw screws

It is screwed with pattern to help removing pattern as draw screws at one end has machine
screw and the other end has a ring where worker use to screw.

Figure 15 draw screw

4. Steps of preparing the mold

 The drag is placed upright on table then pattern is inserted in it covering it with sand.

 Use rammers (mallet, L-mallet) to ensure that sand fill all cavity around the pattern.

 Use strike-off bar to create a flat surface equal to drag surface then drag is flipped.

 Apply a separator on the top of drag to avoid sticking with cope

 The cope is placed on drag and pattern is also inserted where They are guided with
pins and holes to avoid misalignment, down sprue and riser are placed too.

Figure 16 fix upper pattern

Figure 17 put sprue, riser and cope flask

 Cover it with sand and ram the cope well.

  Clean and level the top surface using strike-off bar then finish with a spoon

Figure 18 after cope surface leveling

 Remove sprue and riser then open the mold. spray a little amount of water on
edges.

Figure 19 opened mold

 By using draw spike enlarge cavity to easy extraction of pattern.

 Use draw screws to extract the pattern
 Figure 20 drag after removing pattern

Figure 21 cope after removing pattern

 Create the runner

Figure 22 Runner
 On separate mold create the core using mold box with inserting a support inside it
like thin steel rod

Figure 23 core mold

Figure 24 final core shape

 Put the molds in furnace or expose it to heat

 Close the mold with inserting core inside the mold

Figure 25 final assembly

 Super Heat the required material

 Pour it

Figure 26 pouring molten metal

 Wait for solidification and cooling

 Figure 27 waiting for cooling

 Open the mold

 Clean the workpiece

Figure 28 final product for sand casting

 Figure 29 final product for die casting

 Remove excess unwanted material

5. Difference between sand and die casting

Sand casting Die casting
Mold material Sand steel
Cooling time more than die casting Short cooling time
Surface finish Poor surface finish Better surface finish
machining Require machining after Less machining required
casted than sand casting
Production volumes low high
cost cheap More expensive than sand
Dimensional accuracy poor high
Cast size Medium to large Small to medium