Casting Process

CASTING PATTERNMAKING :
In pattern making, a physical model of
casting, i.e. a pattern is used to make the
mold. The mold is made by packing
some readily formed aggregated
materials, like molding sand, around the
pattern. After the pattern is withdrawn, its
imprint leaves the mold cavity that is
ultimately filled with metal to become the
casting.
n case, the castings is required to be
hollow, such as in the case of pipe
fittings, additional patterns, known as
cores, are used to develop these cavities.

COREMAKING & MOLDING :
In core making, cores are formed,
(usually of sand) that are placed
into a mold cavity to form the
interior surface of the casting.
Thus the annul space between the
mold-cavity surface and the core
is what finally becomes the
casting.
Molding is a process that consists
of different operations essential to
develop a mold for receiving
molten metal
ALLOY MELTING AND POURING :
Melting is a process of preparing
the molten material for casting. It
is generally done in a specifically
designated part of foundry, and
the molten metal is transported to
the pouring area wherein the
molds are filled
CASTING CLEANING :


The casting is separated from the mold
and transported to the cleaning
department.
Burned-on sand and scale are removed.
Excess metal is removed (Fins, wires,
parting line fins, and gates).
Subsequently the casting can be
upgraded using welding or other such as
procedures.
Final testing and inspection to check for
any defects
Advantages:
Improves the surface appearance and finish of casting
Improves overall quality and functionality by removing impurities, such as
sand, scale and excess metal

Finally the sand from the mold is separated and processed through a
reclamation system for further use.
INDUSTRIAL PROCESS DESCRIPTION
The metal casting process has been divided into
the following five major operations:
Obtaining the Casting Geometry :
The process is referred as the study of the
geometry of parts and plans, so as to improve
the life and quality of casting.

Advantages of Good Casting Geometry
Reduces defects, post casting operations, and
rejected castings
Significantly reduce energy and environmental
impacts
Saves energy
Improves overall quality and life of casting

A key part of designing a mold involves the use of
cores. Cores are preformed masses of bonded
sand or some other material that are used to make
the internal passageways of a casting. Castings
may require a single core, a complex assembly of
cores or no cores at all. Like castings, cores are
made in a mold, called a coldbox.
Typically cores are made of sand and may be
combined with other materials that bind the sand
together. Metal cores are used in permanent mold
and diecasting processes. The type of cores used
in each metalcasting process will also be part of
your decision making process.
TYPES OF MOLDING PROCESS
1 Expendable Mold
1.1 Permanent Pattern
1.1.1 Sand Casting
1.1.2 Plaster
Molding
1.2 Expendable
Pattern
1.2.1 Lost Foam
1.2.2 Lost Wax
(investment
casting)

1 Permanent Mold
1.1 Die
1.1.1 Hot Chamber
1.1.2 Cold Chamber
1.1.3Thixotropic

Mold prepertation =) metal heating =) pouring =) cooling =) processing
EXPANDABLE MOLD
PERMANENT PATTERN
SAND CASTING
SAND CASTING

The set of channels through which a molten metal flows
to the mold cavity is called gating system.

Typical gating system consists of a pouring cup and a
sprue receiving the poured melt, runner a channel
through which the melt is supplied to the gates through
which the molten metal enters the mold cavity.
EXPANDABLE MOLD
EXPANDABLE PATTERN
INVESTMENT CASTING
Use gravity to fill the mold.
Mold is destroyed to remove casting
Metal flow is slow
Walls are much thicker than in die casting.
Cycle time is longer than die casting because of inability of mold material
to remove heat.
The investment casting process uses expendable patterns made of
investment casting wax:
The wax patterns are commonly prepared by injection molding technology
which involves injection of wax into a prefabricated die having the same
geometry of the cavity as the desired cast part.
INVESTMENT CASTING
EXPANDABLE MOLD
PERMANENT PATTERN
SHELL MOLDING
Shell moulding is a process for producing simple or complex near
net shape castings, maintaining tight tolerances and a high degree
of dimensional stability. Shell moulding is a method for making high
quality castings. These qualities of precision can be obtained in a
wider range of alloys and with greater flexibility in design than die-
casting and at a lower cost than investment casting.
INVESTMENT CASTING
Shell molding
Advantages

Better surface finish
Better dimensional tolerances.
Reduced Machining.
Less foundry space required.
Semi skilled operators can handle the process.
The process can be mechanized.

Disadvantages

The raw materials are relatively expensive.
The process generates noxious fumes which must be removed.
The size and weight range of castings is limited.
EXPANDABLE MOLD
PERMANENT PATTERN
LOST FOAM CASTING
INVESTMENT CASTING
Lost foam casting (LFC) is a type of investment casting
process that uses foam patterns as a mold. The method
takes advantage of the properties of foam to simply and
inexpensively create castings that would be difficult to
achieve using other casting techniques.
EXPANDABLE MOLD
PERMANENT PATTERN
LOST FOAM CASTING
Lost foam casting (LFC) is a type of investment casting
process that uses foam patterns as a mold. The method
takes advantage of the properties of foam to simply and
inexpensively create castings that would be difficult to
achieve using other casting techniques.
Lost foam casting

Lost foam, is similar to Investment or Lost wax, in
that the medium, or pattern device, is Expendable,
they melt or evaporate away, leaving the cast part.
They both have advantages, for the type of function
they were designed. One Process's advantage,
could be the other Process's weak area.
These points are brought up in the text portion of
Education Section.
PERMANENT MOLD
DIE CASTING
Liquid metal injected into reusable steel mold, or die,
very quickly with high pressures .
Die casting is a process in which the molten metal is
injected into the mold cavity at an increased pressure
The mold used in the die casting process is called a die.

In a cold chamber process, the molten metal is ladled into
the cold chamber for each shot. There is less time exposure of
the melt to the plunger walls or the plunger. This is particularly
useful for metals such as Aluminum, and Copper (and its
alloys) that alloy easily with Iron at the higher temperatures.
PERMANENT MOLD
DIE CASTING

COLD CHAMBER
In a hot chamber process the pressure chamber is connected to
the die cavity is immersed permanently in the molten metal. The inlet
port of the pressurizing cylinder is uncovered as the plunger moves
to the open (unpressurized) position. This allows a new charge of
molten metal to fill the cavity and thus can fill the cavity faster than
the cold chamber process. The hot chamber process is used for
metals of low melting point and high fluidity such as tin, zinc, and
lead that tend not to alloy easily with steel at their melt temperatures.

PERMANENT MOLD
DIE CASTING

HOT CHAMBER
Manifacturing techniques
TERMS OF CASTNG
Riser: A column of metal placed in the mold to feed
the casting as it shrinks and solidifies. Also known
as a "feed head."



Riser: A column of metal placed in the mold to feed the casting as it shrinks and
solidifies. Also known as a "feed head."
Runner: The channel through which the molten metal is carried from the sprue to the
gate.
Cores: A separated part of the mold, made of sand and generally baked, which is used
to create openings and various shaped cavities in the casting.

Gate: A channel through which the molten metal enters the casting cavity.
Sand: A sand which binds strongly without losing its permeability to air or gases.
TERMS OF CASTNG
Binders: Materials used to hold molding sand together.
Parting Line: Joint where mold separates to permit removal of the pattern. The axe
which shows how and where to open the mold
Centrifugal Casting: Process of filling molds by pouring metal into a mold which is
spinning or revolving about an axis. Cast iron pipe can be created using this method.
Chaplet: A metal support used to hold a core in place in a mold. Not used when
a core print will serve.

Draft: Slight taper given to a pattern to allow drawing from the sand.
Pouring: Filling the mold with molten metal.
Shrinkage: The decrease in volume when molten metal solidifies.
SELECTING THE RIGHT METAL CASTING
PROCESS
For any Metal Casting Process, selection of right alloy, size,
shape, thickness, tolerance, texture, and weight, is very vital.
Special requirements such as, magnetism, corrosion, stress
distribution also influence the choice of the Metal Casting
Process.
Views of the Tooling Designer; Foundry / Machine House needs,
customer's exact product requirements, and secondary
operations like painting, must be taken care of before selecting
the appropriate Metal Casting Process.
Tool cost.
Economics of machining versus process costs.
Adequate protection / packaging, shipping constraints,
regulations of the final components, weights and shelf life of
protective coatings also play their part in the Metal Casting
process.


Advantages Disadvantages Recommended
Application
Least Expensive in
small quantities (less
than 100)

Ferrous and non -
ferrous metals may be
cast

Possible to cast very
large parts.

• Least expensive
tooling
Dimensional
accuracy inferior to
other processes,
requires larger
tolerances

Castings usually
exceed calculated
weight

Surface finish of
ferrous castings
usually exceeds 125
RMS
Use when
strength/weight
ratio permits

Tolerances,
surface finish and
low machining cost
does not warrant a
more expensive
process
SAND CASTING
PERMANENT AND SEMI-PERMANENT MOLD
CASTING
Advantages Disadvantages Recommended
Application
Less expensive
than Investment or
Die Castings

Dimensional
Tolerances closer
than Sand Castings

Castings are dense
and pressure tight
Only non-ferrous
metals may be cast
by this process

Less competitive
with Sand Cast
process when three
or more sand cores
are required

Higher tooling cost
than Sand Cast
Use when
process
recommended for
parts subjected to
hydrostatic
pressure

Ideal for parts
having low
profile, no cores
and quantities in
excess of 300
PLASTER CAST
Advantages Disadvantages Recommended
Application
Smooth "As Cast"
finish (25 RMS)

Closer dimensional
tolerance than Sand
Cast

• Intricate
shapes and fine
details including
thinner "As Cast"
walls are possible

• Large parts
cost less to cast than
by Investment
process
More costly than
Sand or Permanent
Mold-Casting

Limited number of
sources

Requires minimum
of 1 deg. draft
Use when parts
require smooth "As
Cast" surface finish
and closer
tolerances than
possible with Sand
or Permanent Mold
Processes
INVESTMENT CAST
Advantages Disadvantages Recommended
Application
Close dimensional
tolerance

Complex shape, fine
detail, intricate core
sections and thin walls
are possible

Ferrous and non-
ferrous metals may be
cast

As-Cast" finish (64 -
125 RMS)
Costs are higher than
Sand, Permanent
Mold or Plaster
process Castings
Use when
Complexity
precludes use of
Sand or Permanent
Mold Castings

The process cost is
justified through
savings in
machining or
brazing

Weight savings
justifies increased
cost
DIE CASTING
Advantages Disadvantages Recommended
Application
Good dimensional
tolerances are
possible

Excellent part-part
dimensional
consistency

Parts require a
minimal post
machining
Economical only in very
large quantities due to
high tool cost

Not recommended for
hydrostatic pressure
applications

For Castings where
penetrant (die) or
radiographic inspection
are not required.

Difficult to guarantee
minimum mechanical
properties
Use when quantity of
parts justifies the high
tooling cost

Parts are not
structural and are
subjected to
hydrostatic pressure