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MME-253 Melting and Casting: by Dr. Muhammad Zafar Zarif

This document discusses melting and casting processes. It begins with an introduction to casting as one of the oldest manufacturing processes where molten metal is poured into a mold and allowed to solidify. The document then covers the history of casting from its origins in Mesopotamia in 3500 BC to modern developments. It describes the scope of the casting industry, noting its use in transportation, construction, aerospace and more. Statistics are provided on the size of the US casting industry and its forecasted growth in sales and jobs.

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Sami Ullah
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100 views21 pages

MME-253 Melting and Casting: by Dr. Muhammad Zafar Zarif

This document discusses melting and casting processes. It begins with an introduction to casting as one of the oldest manufacturing processes where molten metal is poured into a mold and allowed to solidify. The document then covers the history of casting from its origins in Mesopotamia in 3500 BC to modern developments. It describes the scope of the casting industry, noting its use in transportation, construction, aerospace and more. Statistics are provided on the size of the US casting industry and its forecasted growth in sales and jobs.

Uploaded by

Sami Ullah
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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MME-253 Melting and

Casting
by
Dr. Muhammad Zafar Zarif
Recommended Books
1. Principles of Metal Casting by Richard W
Heine, Carl R Loper and Philips C Rosenthal

2. Principles of Foundry Technology by P L Jain

3. Manufacturing Technology by P N Rao

4. Foundry Technology by Peter Beeley


Melting and Casting
• Introduction
• History
• Scope of casting industry
• Advantages of casting process
• Types of foundries
• Basic steps in making casting
A. Introduction
 Casting is an oldest Manufacturing Process in
which parts are produced by pouring molten
metal/or alloy into a desired shape cavity and
allow them to solidify to obtained final product.
 The final product is taken out from the mold by
breaking the mold or taking the mold apart.
 The solidified object is called casting.

 The process is also known as founding


A. Introduction
• Other manufacturing techniques are;
• Forging
• Rolling
• Machining
• Drawing
• Welding and
• Extrusion etc.
• Melting and Casting
Melting and Pouring Temperature
Sr. Metal/Alloy Melting temp. Pouring temp
No. (oC) (oC)
1 Grey cast iron 1380 1520-1590

2 Cast steel 1480 1600-1720

3 Copper (Cu) 1083 1140-1200

4 Nickel (Ni) 1453 1500-1590

5 Aluminium (Al) 660 720-750

6 Zinc (Zn) 420 450-480

7 Lead (Pd) 327 350-390

 This temp difference between M.P & P.T is called Superheating


A. Introduction
What is a Manufacturing?
The process of converting Raw Materials into
products
Inspect various objects around you , Pen, watch,
calculator, telephone, chair and light fixtures
All these objects have different shapes and they have
transformed from various raw materials and
assembled into the shapes that you now see.
A. Introduction
Think about a car:
 It has a lot of parts manufactured and assembled
together to form a complete assembly (in the form
of a car)

Cast iron or Aluminum alloy engine block,


Aluminium alloy rims, crank shaft (Cast/or
Forged)
Engine block
4 cylinders
 Casting process
 Sand Casting

6 cylinders

 Engine blocks are usually made


from Sand casting
 The casted engine block is
finally machined to get the
desired surface finish and
cooling passages.
Crank Shaft

 Cast crankshaft which


was machined to final
dimensions
 Made from the process
of forging (steel) and
Nodular cast iron
(casting)
B. History of casting
• The discovery of the casting Stone mold in single piece
process was done around 3500
B.C in Mesopotamia (Copper
frog)
• Bronze age near 2000 B.C bring
more refinement in casting
process
• Use of core to produced hollow
parts was invented (cores are
made from baked clay)
Bronze age (stone mold with axe
shape
B. History of Casting

Arsenical Copper (4 % As) axes from Oxfordshire, England


Bronze age
B. History of Casting

 Bronze panel A good example


of art casting (Vatican city)
 Tin Bronze (5 to 10 % Sn)
produced beautiful and easily
polished cast surface
B. History of Casting
• Casting technology was greatly improved by
Chinese around 1500 B.C. They specialized in
multi-piece mold to produced highly intricate
jobs. Perfecting the mold to last details so that
hardly any finishing work required (such mold
found during archaeological excavations in
China)
• Evidence found that iron founding/ or casting
was started in 1000 B.C in Persia and Syria
• In 460 B.C Bronze statue of Zeus was cast in
Greece.
B. History of Casting
• In 1480 A.D V. Biringuccio first to document the foundry
process in writing (also know as the father of foundry
industry)
• In 1750 A.D Benjamin Huntsman produced cast crucible
steel in England
• Centrifugal casting process was developed in 1809,
England
• 1869 AFS was established/formed (American
Foundrymen’s society)
• In 1971 Rheo-casting was developed at MIT
• 1996 cast metal matrix composites were first used in
automobile
In Modern World
• Automobile components
-Engine block
-Car RIMS
-Crank shafts
• Aerospace components e.g., Turbine blades
• Many industrial components
-Motor casing
-lathe machine coverings
-Fly wheels
-Other machine parts
-Nozzles, elbows, Tees etc.
c. Scope of casting industry

• Castings are used in transportation,


communications, construction, agriculture,
power generators, in aerospace and atomic
energy applications.
• Castings are produced almost everywhere in
the industry involving manufacturing.
Scope of Casting Industry

The scope of metal casting industry has broadened


up in modern world. It use is not only limited to
metal products, but the application of casting
products also include plastic product, composites,
civil and building infrastructure development,
bridge construction etc.
According to the 2019 Metal casting Industry Forecast

& Trends report published by the American Foundry

Society (AFS), US metal casting industry sales reached

up to $33.1 billion in 2018, a 10% increase over 2017.

Growth is expected to continue in 2019 with a 1.9% to

$33.7 billion in casting sales. In the short-term, through

2021, the US metal casting industry has a forecasted

annual growth rate of 2.4%.


Scope of casting Industry

From future perspective, the growth trend


and additional scope of foundry industry
will require skilled manpower in this field.
This will create new job opportunities in
metal casting industry to huge number of
metal casting professionals.
Thanks
We can also arrange a live meeting for further
discussion and understanding of this course.

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