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1 Casting Intro

Casting is a process where molten metal is poured into a mold and solidifies into the shape of the mold cavity. It is one of the oldest shaping processes dating back 6000 years. Casting can create complex part geometries and internal and external shapes. There are two main categories of casting processes: expendable mold processes where the mold is sacrificed, and permanent mold processes where a reusable metal mold is used. Common casting steps include melting metal, pouring it into a mold, allowing it to solidify, breaking the mold, and cleaning the casting.

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Mayank Sharma
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57 views15 pages

1 Casting Intro

Casting is a process where molten metal is poured into a mold and solidifies into the shape of the mold cavity. It is one of the oldest shaping processes dating back 6000 years. Casting can create complex part geometries and internal and external shapes. There are two main categories of casting processes: expendable mold processes where the mold is sacrificed, and permanent mold processes where a reusable metal mold is used. Common casting steps include melting metal, pouring it into a mold, allowing it to solidify, breaking the mold, and cleaning the casting.

Uploaded by

Mayank Sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Casting Intro

1
Casting
• In the casting processes, a material is first
melted, heated to proper temperature, and then
poured into a cavity or mold that holds it in the
desired shape during cool-down and
solidification.

2
Casting
• Casting is a process in which molten metal flows
by gravity or other force into a mold where it
solidifies in the shape of the mold cavity.
• The term casting is also applied to the part that
is made by this process.
• It is one of the oldest shaping processes, dating
back 6000 years.
• The variety of casting processes use different
pouring methods (gravity, vacuum, low
pressure, or high pressure)
3
Casting

4
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

5
Disadvantages of Casting
• Different disadvantages for different casting
processes:
– 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

6
Parts Made by Casting
• Big parts
– Engine blocks and heads for automotive vehicles,
wood burning stoves, machine frames, railway
wheels, pipes, church bells, big statues, pump
housings
• Small parts
– Dental crowns, jewelry, small statues, frying pans
• All varieties of metals can be cast, ferrous and
nonferrous
7
Two Categories of Casting Processes

8
Two Categories of Casting Processes
1. Expendable mold processes - mold is sacrificed
to remove part
– Advantage: more complex shapes possible
– Disadvantage: production rates often limited by
time to make mold rather than casting itself
2. Permanent mold processes - mold is made of
metal and can be used to make many castings
– Advantage: higher production rates
– Disadvantage: geometries limited by need to open
mold 9
Expendable mold processes

10
Overview of Casting Technology
• Casting is usually performed in a foundry
• Foundry = factory equipped for making molds,
melting and handling molten metal, performing
the casting process, and cleaning the finished
casting
• Workers who perform casting are called
foundrymen

11
Casting Steps

• Steps in casting seem simple:

– Melt the metal

– Pour it into a mold

– Let it freeze

12
Casting Steps
1. Pour the molten metal into sand mold
2. Allow time for metal to solidify
3. Break up the mold to remove casting
4. Clean and inspect casting
– Separate gating and riser system
5. Heat treatment of casting is sometimes
required to improve metallurgical properties

13
Sand Casting Production Sequence

14
Sand Casting Steps

15

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