Foundry Workshop

(ME-110)

Department of Mechanical Engineering

Indian Institute of Technology Patna
 Introduction
What is a Foundry?
Facility where metal casting processes are carried out.

Casting means pouring molten metal into a mold with a

cavity of the shape to be made, and allowing it to solidify.
The solidified object is called the casting.

By this process, intricate parts can be given strength

and rigidity frequently not obtainable by any other
manufacturing process.

The mold, into which the metal is poured, is made of

some heat resisting material. Sand is most often used as
it resists the high temperature of the molten metal.
 Introduction

• Casting is one of the oldest industrial processes

• There are different casting processes.

The focus here is: “GREEN SAND” CASTING

Applications

Engine blocks,
axles Turbine blades
in jet engines

Aluminum
V6 Engine pots
 Advantages

 Molten material can flow into very small sections so that intricate shapes,
complex geometries, internal cavities, hollow sections can be made by this
process.

 It is possible to cast practically any material that is ferrous or non-ferrous.

 The necessary tools required for casting molds are very simple and
inexpensive.

 There are certain parts made from metals and alloys that can only be
processed this way.

 Size and weight of the product is not a limitation for the casting process

Low wastage, highly economical.

 Limitations

 Low dimensional accuracy and low surface finish.

 Allowance required.

 Labour intensive process.

 Introduction
Sand Casting
Basic materials & equipment for green sand-casting

Pattern
(a copy of the shape you
want to produce, made of
wood, plastic or metal)

Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish
Top and bottom mold forms
(made of metal, open at top and bottom)

Container of molten metal Rammer (tool to compact the sand;

(filled from furnace) often a pressing machine is used)
 Casting Terminology

Flask: A metal or wood frame, without fixed top or bottom, in which the mold is
formed. Depending upon the position of the flask in the molding structure, it is
referred to by various names such as drag – lower molding flask, cope –
upper molding flask, cheek – intermediate molding flask used in three piece
molding.
Pattern: It is the replica of the final object to be made. The mold cavity is made
with the help of pattern.
Parting line: This is the dividing line between the two molding flasks that
makes up the mold.
Facing sand: The small amount of carbonaceous material sprinkled on the
inner surface of the mold cavity to give a better surface finish to the castings.
 Casting Terminology

Core: A separate part of the mold, made of sand and generally baked,
which is used to create openings and various shaped cavities in the
castings.
Pouring basin: A small funnel shaped cavity at the top of the mold into
which the molten metal is poured.
Sprue: The passage through which the molten metal, from the pouring
basin, reaches the mold cavity. In many cases it controls the flow of metal
into the mold.
Runner: The channel through which the molten metal is carried from the
sprue to the gate.
Gate: A channel through which the molten metal enters the mold cavity.
 Casting Terminology

Riser: A column of molten metal placed in the mold to feed the castings
as it shrinks and solidifies. Also known as “feed head”.
Vent: Small opening in the mold to facilitate escape of air and gases.
 Steps in making Sand Casting
Pattern making
Melting and pouring
Core making
Cleaning
Molding

https://www.youtube.com/watch?v=fCyaJ8Q76U8&ab_channel=ForceBeyondInc
 Pattern
Types of patterns used in sand casting:
(a) Single-piece or solid pattern : used for simple shape (one surface is flat)
(b) Two-piece or split pattern (a little complex geometry)
(c) match‑plate pattern complex shape for mass production (Piston rings)

Metal
Wood
Material for Pattern Plastic
Wax
 Pattern
Allowances in Pattern
Shrinkage or contraction allowance (+ve)
Draft or taper allowance (+ve)
Machining or finish allowance (+ve)
Rapping Allowance (-ve)
Distortion or camber allowance (+ve)

Pattern Having No Draft on Vertical Edges Pattern Having Draft on Vertical Edges
 Cooling curve of a pure metal during casting

 A pure metal solidifies at a constant temperature equal to its freezing

point (same as melting point)
 Core Making

• Used for making cavities and hollow projections.

• All sides of core are surrounded by the molten metal and are
therefore subjected to much more severe thermal and mechanical
conditions and as a result the core sand should be of higher
strength than the moulding sand.
 Molding Sand Composition
•Base sand
•Binder
•Moisture

Base Sand
Silica sand is most commonly used base sand. Other base sands that
are also used for making mold are zircon sand, Chromite sand, and
olivine sand. Silica sand is cheapest among all types of base sand and
it is easily available.

Binder
Binders are of many types such as:
1.Clay binders,
2.Organic binders and
3.Inorganic binders

Clay binders are most commonly used binding agents mixed with the
molding sands to provide the strength.
Contd.
 Molding Sand Composition
The most popular clay types are:
Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O) and Bentonite (Al2O3 4 SiO2 nH2O)
Of the two the Bentonite can absorb more water which increases its bonding
power.

Moisture
Clay acquires its bonding action only in the presence of the required amount of
moisture. When water is added to clay, it penetrates the mixture and forms a
microfilm, which coats the surface of each flake of the clay. The amount of water
used should be properly controlled. This is because a part of the water, which
coats the surface of the clay flakes, helps in bonding, while the remainder helps in
improving the plasticity.
A Typical Composition of Molding Sand
Weight Percent
Composition
(%)
Silica sand 88-90
Clay (Sodium 8
Bentonite)
Water 2-4
 Properties of Molding Material

 Refractoriness: ability to withstand high temperature

 Permeability: Porosity of the moulding sand-- ability to allow gases to escape.

 Green Strength: The molding sand that contains moisture is termed as green
sand. The green sand particles must have the ability to stick to each other to
impart sufficient strength to the mold. The green sand must have enough strength
so that the constructed mold retains its shape.

 Flowability: ability of sand to flow in corners.

 Adhesive property

 Cohesive property

 Collapsibility: ability to be destroyed easily after casting solidification

 Gating Systems
Gating design should be proper to avoid erosion, turbulence and
splashing so that metals can be easily casted.
 Gating Systems
Types of Gating System
Top Gate: Causes turbulence in the mould cavity, it is prone to form dross,
favourable temperature gradient towards the gate, only for ferrous alloys.

Bottom Gate: No mould erosion, used for very deep moulds, higher
pouring time, Causes unfavourable temperature gradients.

Parting Gate: most widely used gate, easiest and most economical in
preparation.

2
1
 Riser

• Risers are added reservoirs designed to feed liquid metal to

the solidifying casting as a means of compensating for
solidification shrinkage.

• To perform this function, the risers must solidify after the

casting.

• According to Chvorinov's rule, a good shape for a riser

would be one that has a long freezing time (i.e., a small
surface area per unit volume).

Solidification time (ts) = γ(V/A)2

 Pouring of Molten Metals
Ladle : Container or vessel used in the metal casting process to
transfer and pour molten metal into molds.
Two types of ladles are used:
 Casting defects
Casting defects refer to imperfections or irregularities that occur during the
process of casting--Casting defects can affect the quality, strength, and
appearance of the final cast component.
o Porosity: This defect occurs when gas bubbles or voids are trapped -----weaken the
structure of the casting and reduce its mechanical properties.
o Shrinkage: when the casting solidifies and contracts, causing voids or cavities to
form ----- result in dimensional inaccuracies and reduced mechanical strength.
o Inclusions: Inclusions are foreign materials or impurities that are trapped in the
casting during the casting process. They can include slag, sand, or other
contaminants, and can result in weak spots or reduced mechanical properties in the
casting.
 Casting defects
o Cold shuts: When two or more streams of molten material do not properly
fuse together during the casting process, resulting in a surface defect where
the material does not fully fill the mold cavity.
o Misruns: When the molten material does not completely fill the mold cavity,
resulting in a casting that is not fully formed. Misruns can result in incomplete
or misshapen castings.
o Hot tears: Hot tears occur during the solidification of the casting when there
is differential cooling, causing the material to crack or tear. Hot tears can
weaken the casting and reduce its structural integrity.
 Prevention of Impurities
Impurities in the molten metal are prevented from reaching the mould cavity
by providing:
• Strainer : to filter impurities, reduce turbulence, and ensure a smooth
and consistent flow of metal.
• Skim bob : This traps lighter and heavier impurities in the horizontal flow.
 Safety Precautions

 Wear leather work boots.

 Wear trouser and long sleeve shirt.

 Wear loose-fitting leather clothes, or at least clothes made of

a material, which is fairly flame resistant.

 Welder's gloves or other leather gloves.

 Safety glasses and full-face shield as well.

 Don’t go closer to the furnace.