Ch11 More Metal Casting

METAL CASTING PROCESSES
1.
2.
3.
4.
5.
6.
7.
Sand Casting
Other Expendable Mold Casting Processes
Permanent Mold Casting Processes
Foundry Practice
Casting Quality
Metals for Casting
Product Design Considerations
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
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
Overview of Sand Casting

Most widely used casting process, accounting for a
significant majority of total tonnage cast
Nearly all alloys can be sand casted, including metals
with high melting temperatures, such as steel, nickel,
and titanium
Castings range in size from small to very large
Production quantities from one to millions
Figure 11.1 A large sand casting weighing over

680 kg (1500 lb) for an air compressor frame
(photo courtesy of Elkhart Foundry).

Making the Sand Mold

The cavity in the sand mold
is formed by packing sand
around a pattern, then
separating the mold into two
halves and removing the
pattern
The mold must also contain
gating and riser system
If casting is to have internal
surfaces, a core must be
included in mold
A new sand mold must be
made for each part produced
Steps in Sand Casting

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

Figure is from
www.themetalcasting.com
The Pattern
A fullsized model of the part, slightly enlarged to account for
shrinkage and machining allowances in the casting
Pattern materials:
Wood - common material because it is easy to work, but
it warps
Metal - more expensive to make, but lasts much longer
Plastic - compromise between wood and metal
Top center is the clay original, then the two part

mold used for casting the lead at above, and
2007 John Wiley & Sons,plaster
Inc.
M P Groover, Fundamentals of
wax cast from mold, sprued for better brass casting,
Modern Manufacturing 3/enot yet cast. 2008-01-12.
homepages.waymark.net/mikefirth/tapper6881b.jpg
Types of Patterns
Figure 11.3 Types of patterns used in sand casting:
(a) solid pattern
(b) split pattern
(c) matchplate pattern
(d) cope and drag pattern

Core
Fullscale model of interior surfaces of part
It is inserted into the mold cavity prior to pouring
The molten metal flows and solidifies between the mold
cavity and the core to form the casting's external and
internal surfaces
May require supports to hold it in position in the mold cavity
during pouring, called chaplets
2007
John
& held
Sons,
Inc. inMtheP mold
Groover,
Figure
11.4Wiley
(a) Core
in place
cavity Fundamentals
by chaplets, (b) of
chaplet design,
Modernpossible
Manufacturing
3/e (c) casting with internal cavity.
Desirable Mold Properties

Strength to maintain shape and resist erosion
Permeability to allow hot air and gases to pass
through voids in sand
Thermal stability to resist cracking on contact with
molten metal
Collapsibility ability to give way and allow casting
to shrink without cracking the casting
Reusability can sand from broken mold be reused
to make other molds?

Foundry Sands
Silica (SiO2) or silica mixed with other minerals
Good refractory properties capacity to endure high temperatures
Small grain size yields better surface finish on the cast part
Large grain size is more permeable, allowing gases to escape
during pouring
Irregular grain shapes strengthen molds due to interlocking,
compared to round grains
Disadvantage: interlocking tends to reduce permeability
Binders
Sand is held together by a mixture of water and bonding clay
Typical mix: 90% sand, 3% water, and 7% clay
Other bonding agents also used in sand molds:
Organic resins (e g , phenolic resins)
Inorganic binders (e g , sodium silicate and phosphate)
Additives are sometimes combined with the mixture to
increase strength and/or permeability
Types of Sand Mold

Greensand molds - mixture of sand, clay, and
water;
Green" means mold contains moisture at time of
pouring
Drysand mold - organic binders rather than clay
And mold is baked to improve strength
Skindried mold - drying mold cavity surface of a
greensand mold to a depth of 10 to 25 mm, using
torches or heating lamps

Buoyancy in Sand Casting Operation

During pouring, buoyancy of the molten metal tends
to displace the core, which can cause casting to be
defective
Force tending to lift core = weight of displaced liquid
less the weight of core itself
Fb = Wm Wc
where Fb = buoyancy force; Wm = weight of molten
metal displaced; and Wc = weight of core

Other Expendable Mold Processes

Shell Molding
Vacuum Molding
Expanded Polystyrene Process
Investment Casting
Plaster Mold and Ceramic Mold Casting
Here is a good reference web site:
http://www.custompartnet.com/wu/SandCasting

Shell Molding
Casting process in which the mold is a thin shell of
sand held together by thermosetting resin binder
Figure 11.5 Steps in shellmolding: (1) a matchplate or

copeanddrag metal pattern is heated and placed over a
John Wiley
& Sons, sand
Inc. mixed
M P Groover,
Fundamentals
box containing
with thermosetting
resin. of
2007
Shell Molding
Figure 11.5 Steps in shellmolding: (2) box is inverted so that
sand and resin fall onto the hot pattern, causing a layer of the
mixture to partially cure on the surface to form a hard shell; (3)
box is repositioned so that loose uncured particles drop away;

Shell Molding
Figure 11.5 Steps in shellmolding: (4) sand shell is heated in
oven for several minutes to complete curing; (5) shell mold is
stripped from the pattern;

Shell Molding
From www.janfa.com
Figure 11.5 Steps in shellmolding: (6) two halves of the shell mold are
assembled, supported by sand or metal shot in a box, and pouring is
accomplished;
(7)&the
finished
with sprue
removed.
2007
John Wiley
Sons,
Inc.casting
M P Groover,
Fundamentals
of
Advantages and Disadvantages

Advantages of shell molding:
Smoother cavity surface permits easier flow
of molten metal and better surface finish
Good dimensional accuracy - machining often
not required
Mold collapsibility minimizes cracks in casting
Can be mechanized for mass production
Disadvantages:
More expensive metal pattern
Difficult to justify for small quantities

Uses a mold of sand packed around a polystyrene foam pattern
which vaporizes when molten metal is poured into mold
Other names: lostfoam process, lost pattern process,
evaporativefoam process, and fullmold process
Polystyrene foam pattern includes sprue, risers, gating system,
and internal cores (if needed)
Mold does not have to be opened into cope and drag sections
From www.wtec.org/loyola/casting/fh05_20.jpg

Figure
11.7
Expanded polystyrene
casting process: pattern of
Modern
Manufacturing
3/e
polystyrene is coated with refractory compound;
Figure 11.7 Expanded polystyrene

casting process: (3) molten metal is
Figure 11.7 Expanded
poured into the portion of the pattern
polystyrene casting process:
that forms the pouring cup and sprue.
(2) foam pattern is placed in
As the metal enters the mold, the
mold box, and sand is
is vaporizedof
ahead
2007 compacted
John Wiley
& Sons,
Inc. M Ppolystyrene
Groover, foam
Fundamentals
around
the pattern;
of the advancing liquid, thus the
resulting mold cavity is filled.

Advantages of expanded polystyrene process:
Pattern need not be removed from the mold
Simplifies and speeds moldmaking, because two
mold halves are not required as in a conventional
greensand mold
Disadvantages:
A new pattern is needed for every casting
Economic justification of the process is highly
dependent on cost of producing patterns
Applications:
Mass production of castings for automobile
engines
Automated and integrated manufacturing
systems are used to
1. Mold the polystyrene foam patterns and then
2. Feed them to the downstream casting
operation

Investment Casting (Lost Wax Process)

A pattern made of wax is coated with a refractory
material to make mold, after which wax is melted
away prior to pouring molten metal
"Investment" comes from a less familiar definition of
"invest" - "to cover completely," which refers to
coating of refractory material around wax pattern
It is a precision casting process - capable of
producing castings of high accuracy and intricate
detail

Investment Casting
Figure 11.8 Steps in investment casting: (1) wax patterns are

produced, (2) several patterns are attached to a sprue to form
a pattern tree

Investment Casting
Figure 11.8 Steps in investment casting: (3) the pattern tree is coated
with a thin layer of refractory material, (4) the full mold is formed by
covering the coated tree with sufficient refractory material to make
it rigid

Investment Casting
Figure 11.8 Steps in investment casting: (5) the mold is held in an

inverted position and heated to melt the wax and permit it to drip out
of the cavity, (6) the mold is preheated to a high temperature, the
molten metal is poured, and it solidifies

Investment Casting
Figure 11.8 Steps in investment casting: (7) the mold is

broken away from the finished casting and the parts are
separated
from
the M
sprue
John Wiley
& Sons,
Inc.
P Groover, Fundamentals of
2007
Investment Casting
Figure 11 9 A onepiece compressor stator with 108

separate airfoils made by investment casting (photo
courtesy of Howmet Corp.).


Advantages of investment casting:
Parts of great complexity and intricacy can be
cast
Close dimensional control and good surface
finish
Wax can usually be recovered for reuse
Additional machining is not normally required
this is a net shape process
Disadvantages
Many processing steps are required
Relatively expensive process
Plaster Mold Casting

Similar to sand casting except mold is made of plaster
of Paris (gypsum CaSO42H2O)
In mold-making, plaster and water mixture is poured
over plastic or metal pattern and allowed to set
Wood patterns not generally used due to
extended contact with water
Plaster mixture readily flows around pattern,
capturing its fine details and good surface finish


Advantages of plaster mold casting:
Good accuracy and surface finish
Capability to make thin crosssections
Disadvantages:
Mold must be baked to remove moisture,
which can cause problems in casting
Mold strength is lost if over-baked
Plaster molds cannot stand high
temperatures, so limited to lower melting
point alloys
Ceramic Mold Casting

Similar to plaster mold casting except that mold is
made of refractory ceramic material that can
withstand higher temperatures than plaster
Can be used to cast steels, cast irons, and other
hightemperature alloys
Applications similar to those of plaster mold casting
except for the metals cast
Advantages (good accuracy and finish) also similar

Permanent Mold Casting Processes

Economic disadvantage of expendable mold
casting: a new mold is required for every casting
In permanent mold casting, the mold is reused many
times
The processes include:
Basic permanent mold casting
Die casting
Centrifugal casting

The Basic Permanent Mold Process

Uses a metal mold constructed of two sections
designed for easy, precise opening and closing
Molds used for casting lower melting point alloys are
commonly made of steel or cast iron
Molds used for casting steel must be made of
refractory material, due to the very high pouring
temperatures

Permanent Mold Casting
Figure 11.10 Steps in permanent mold casting: (1) mold is

preheated and coated

Permanent Mold Casting
Figure 11.10 Steps in permanent mold casting: (2) cores (if used)
are inserted and mold is closed, (3) molten metal is poured into
mold,
where
solidifies.
2007the
John
Wiley
& itSons,
Inc. M P Groover, Fundamentals of
Advantages and Limitations

Advantages of permanent mold casting:
Good dimensional control and surface finish
More rapid solidification caused by the cold
metal mold results in a finer grain structure,
so castings are stronger
Limitations:
Generally limited to metals of lower melting
point
Simpler part geometries compared to sand
casting because of need to open the mold
High cost of mold
Applications of Permanent Mold Casting

Due to high mold cost, process is best suited to high
volume production and can be automated
accordingly
Typical parts: automotive pistons, pump bodies, and
certain castings for aircraft and missiles
Metals commonly cast: aluminum, magnesium,
copperbase alloys, and cast iron

Die Casting
A permanent mold casting process in which molten
metal is injected into mold cavity under high
pressure
Pressure is maintained during solidification, then
mold is opened and part is removed
Molds in this casting operation are called dies;
hence the name die casting
Use of high pressure to force metal into die cavity is
what distinguishes this from other permanent mold
processes
Die Casting Machines
Designed to hold and accurately close two mold

halves and keep them closed while liquid metal is
forced into cavity
Two main types:
1. Hotchamber machine
2. Coldchamber machine

Hot-Chamber Die Casting

Metal is melted in a container, and a piston injects
liquid metal under high pressure into the die
High production rates - 500 parts per hour not
uncommon
Applications limited to low meltingpoint metals that
do not chemically attack plunger and other
mechanical components
Casting metals: zinc, tin, lead, and magnesium

Hot-Chamber Die Casting
Figure 11.13 Cycle in hotchamber casting: (1) with die closed and
plunger withdrawn, molten metal flows into the chamber (2)
2007 John
Wiley
& Sons,
M P Groover,
Fundamentals
of
plunger
forces
metal Inc.
in chamber
to flow into
die, maintaining
pressure during cooling
and solidification.
Modern Manufacturing
3/e
ColdChamber Die Casting Machine

Molten metal is poured into unheated chamber
from external melting container, and a piston
injects metal under high pressure into die cavity
High production but not usually as fast as
hotchamber machines because of pouring step
Casting metals: aluminum, brass, and
magnesium alloys
Advantages of hotchamber process favor its use
on low meltingpoint alloys (zinc, tin, lead)

ColdChamber Die Casting
Figure 11.14 Cycle in coldchamber casting: (1) with die

closed and ram withdrawn, molten metal is poured into
the chamber
John Wiley
& Sons, Inc. M P Groover, Fundamentals of
2007
ColdChamber Die Casting
Figure 11.14 Cycle in coldchamber casting: (2) ram forces metal

to flow into die, maintaining pressure during cooling and
solidification.

Molds for Die Casting

Usually made of tool steel, mold steel, or maraging
steel
Tungsten and molybdenum (good refractory
qualities) used to die cast steel and cast iron
Ejector pins required to remove part from die when it
opens
Lubricants must be sprayed into cavities to prevent
sticking

Advantages and Limitations

Advantages of die casting:
Economical for large production quantities
Good accuracy and surface finish
Thin sections are possible
Rapid cooling provides small grain size and
good strength to casting
Disadvantages:
Generally limited to metals with low metal
points
Part geometry must allow removal from die
Centrifugal Casting
A family of casting processes in which the mold is
rotated at high speed so centrifugal force distributes
molten metal to outer regions of die cavity
The group includes:
True centrifugal casting
Semicentrifugal casting
Centrifuge casting

True Centrifugal Casting

Molten metal is poured into rotating mold to produce a
tubular part
In some operations, mold rotation commences after
pouring rather than before
Parts: pipes, tubes, bushings, and rings
Outside shape of casting can be round, octagonal,
hexagonal, etc , but inside shape is (theoretically)
perfectly round, due to radially symmetric forces

True Centrifugal Casting

Figure 11.15 Setup for true centrifugal casting.

Semicentrifugal Casting
Centrifugal force is used to produce solid castings
rather than tubular parts
Molds are designed with risers at center to supply
feed metal
Density of metal in final casting is greater in outer
sections than at center of rotation
Often used on parts in which center of casting is
machined away, thus eliminating the portion where
quality is lowest
Examples: wheels and pulleys
Centrifuge Casting
Mold is designed with part cavities located away from
axis of rotation, so that molten metal poured into
mold is distributed to these cavities by centrifugal
force
Used for smaller parts
Radial symmetry of part is not required as in other
centrifugal casting methods

Furnaces for Casting Processes

Furnaces most commonly used in foundries:
Cupolas
Direct fuelfired furnaces
Crucible furnaces
Electricarc furnaces
Induction furnaces

Cupolas
Vertical cylindrical furnace equipped with tapping spout
near base
Used only for cast irons
Although other furnaces are also used, the
largest tonnage of cast iron is melted in cupolas
The "charge," consisting of iron, coke, flux, and
possible alloying elements, is loaded through a
charging door located less than halfway up height of
cupola

Direct FuelFired Furnaces

Small openhearth in which charge is heated by natural
gas fuel burners located on side of furnace
Furnace roof assists heating action by reflecting
flame down against charge
At bottom of hearth is a tap hole to release molten
metal
Generally used for nonferrous metals such as
copperbase alloys and aluminum

Crucible Furnaces
Metal is melted without direct contact with burning fuel
mixture
Sometimes called indirect fuelfired furnaces
Container (crucible) is made of refractory material
or hightemperature steel alloy
Used for nonferrous metals such as bronze, brass,
and alloys of zinc and aluminum
Three types used in foundries: (a) liftout type, (b)
stationary, (c) tilting

Crucible Furnaces
Figure 11.19 Three types of crucible furnaces: (a) liftout crucible,
(b) stationary pot, from which molten metal must be ladled,
and (c) tilting-pot furnace.

ElectricArc Furnaces
Charge is melted by heat generated from an electric arc
High power consumption, but electricarc furnaces can be
designed for high melting capacity
Used primarily for melting steel

Induction Furnaces
Uses alternating current passing through a coil to develop magnetic
field in metal
Induced current causes rapid heating and melting
Electromagnetic force field also causes mixing action in liquid metal
Since metal does not contact heating elements, environment can
be closely controlled to produce molten metals of high quality and
purity
Melting steel, cast iron, and aluminum alloys are common
applications in foundry work

Ladles
Moving molten metal from melting furnace to
mold is sometimes done using crucibles
More often, transfer is accomplished by ladles
Figure 11.21 Two common types of ladles: (a) crane ladle,

John Wiley
& Sons,
Inc.ladle.
M P Groover, Fundamentals of
and (b)
twoman
2007
Additional Steps After Solidification
Trimming
Removing the core
Surface cleaning
Inspection
Repair, if required
Heat treatment

Trimming
Removal of sprues, runners, risers, partingline flash,
fins, chaplets, and any other excess metal from the
cast part
For brittle casting alloys and when cross sections
are relatively small, appendages can be broken off
Otherwise, hammering, shearing, hacksawing,
bandsawing, abrasive wheel cutting, or various
torch cutting methods are used

Removing the Core

If cores have been used, they must be removed
Most cores are bonded, and they often fall out of
casting as the binder deteriorates
In some cases, they are removed by shaking
casting, either manually or mechanically
In rare cases, cores are removed by chemically
dissolving bonding agent
Solid cores must be hammered or pressed out

Surface Cleaning
Removal of sand from casting surface and otherwise
enhancing appearance of surface
Cleaning methods: tumbling, airblasting with coarse
sand grit or metal shot, wire brushing, buffing, and
chemical pickling
Surface cleaning is most important for sand casting
In many permanent mold processes, this step
can be avoided
Defects are possible in casting, and inspection is
needed to detect their presence
Heat Treatment
Castings are often heat treated to enhance
properties
Reasons for heat treating a casting:
For subsequent processing operations such as
machining
To bring out the desired properties for the
application of the part in service

Casting Quality
There are numerous opportunities for things to go
wrong in a casting operation, resulting in quality
defects in the product
The defects can be classified as follows:
General defects common to all casting processes
Defects related to sand casting process

General Defects: Misrun

A casting that has solidified before completely
filling mold cavity
Figure 11.22 Some common defects in castings: (a) misrun

General Defects: Cold Shut

Two portions of metal flow together but there is
a lack of fusion due to premature freezing
Figure 11.22 Some common defects in castings: (b) cold shut

General Defects: Cold Shot

Metal splatters during pouring and solid globules
form and become entrapped in casting
Figure 11.22 Some common defects in castings: (c) cold shot

General Defects: Shrinkage Cavity

Depression in surface or internal void caused by
solidification shrinkage that restricts amount of
molten metal available in last region to freeze
2007
Sons, Inc.
M in
P Groover,
Fundamentals
of
Figure John
11.22Wiley
Some&
common
defects
castings: (d)
shrinkage cavity
Sand Casting Defects: Sand Blow

Balloonshaped gas cavity caused by release of
mold gases during pouring
Figure 11.23 Common defects in sand castings: (a) sand blow

Sand Casting Defects: Pin Holes

Formation of many small gas cavities at or slightly
below surface of casting
Figure 11.23 Common defects in sand castings: (b) pin holes

2007
John Wiley & Sons, Inc. M P Groover, Fundamentals of
Sand Casting Defects: Penetration

When fluidity of liquid metal is high, it may penetrate
into sand mold or core, causing casting surface to
consist of a mixture of sand grains and metal
Figure 11.23 Common defects in sand castings: (e) penetration

Sand Casting Defects: Mold Shift

A step in cast product at parting line caused by
sidewise relative displacement of cope and drag
Figure 11.23 Common defects in sand castings: (f) mold shift

Foundry Inspection Methods

Visual inspection to detect obvious defects such as
misruns, cold shuts, and severe surface flaws
Dimensional measurements to insure that
tolerances have been met
Metallurgical, chemical, physical, and other tests
concerned with quality of cast metal

Metals for Casting

Most commercial castings are made of alloys rather
than pure metals
Alloys are generally easier to cast, and properties
of product are better
Casting alloys can be classified as:
Ferrous
Nonferrous

Ferrous Casting Alloys: Cast Iron

Most important of all casting alloys
Tonnage of cast iron castings is several times that of
all other metals combined
Several types: (1) gray cast iron, (2) nodular iron, (3)
white cast iron, (4) malleable iron, and (5) alloy cast
irons
Typical pouring temperatures 1400C (2500F),
depending on composition

Ferrous Casting Alloys: Steel

The mechanical properties of steel make it an
attractive engineering material
The capability to create complex geometries makes
casting an attractive shaping process
Difficulties when casting steel:
Pouring temperature of steel is higher than for
most other casting metals 1650C (3000F)
At such temperatures, steel readily oxidizes, so
molten metal must be isolated from air
Molten steel has relatively poor fluidity
Nonferrous Casting Alloys: Aluminum

Generally considered to be very castable
Pouring temperatures low due to low melting
temperature of aluminum
Tm = 660C (1220F)
Properties:
Light weight
Range of strength properties by heat treatment
Easy to machine

Nonferrous Casting Alloys: Copper Alloys

Includes bronze, brass, and aluminum bronze
Properties:
Corrosion resistance
Attractive appearance
Good bearing qualities
Limitation: high cost of copper
Applications: pipe fittings, marine propeller blades,
pump components, ornamental jewelry

Nonferrous Casting Alloys: Zinc Alloys

Highly castable, commonly used in die casting
Low melting point melting point of zinc Tm = 419C
(786F)
Good fluidity for ease of casting
Properties:
Low creep strength, so castings cannot be
subjected to prolonged high stresses


Geometric simplicity:
Although casting can be used to produce
complex part geometries, simplifying the part
design usually improves castability
Avoiding unnecessary complexities:
Simplifies moldmaking
Reduces the need for cores
Improves the strength of the casting


Corners on the casting:
Sharp corners and angles should be avoided,
since they are sources of stress concentrations
and may cause hot tearing and cracks
Generous fillets should be designed on inside
corners and sharp edges should be blended


Draft Guidelines:
In expendable mold casting, draft facilitates
removal of pattern from mold
Draft = 1 for sand casting
In permanent mold casting, purpose is to aid in
removal of the part from the mold
Draft = 2 to 3 for permanent mold processes
Similar tapers should be allowed if solid cores are
used
Draft
Minor changes in part design can reduce need for
coring
Figure 11.25 Design change to eliminate the need for using a

core: (a) original design, and (b) redesign.


Dimensional Tolerances and Surface Finish:
Significant differences in dimensional
accuracies and finishes can be achieved in
castings, depending on process:
Poor dimensional accuracies and finish for
sand casting
Good dimensional accuracies and finish for
die casting and investment casting


Machining Allowances:
Almost all sand castings must be machined to
achieve the required dimensions and part
features
Additional material, called the machining
allowance, is left on the casting in those surfaces
where machining is necessary
Typical machining allowances for sand castings
are around 1.5 and 3 mm (1/16 and 1/4 in)


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METAL CASTING PROCESSES

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Two Categories of Casting Processes

Overview of Sand Casting

Figure 11.1 A large sand casting weighing over

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Making the Sand Mold

Steps in Sand Casting

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Top center is the clay original, then the two part

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Desirable Mold Properties

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e

increase strength and/or permeability

Types of Sand Mold

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Buoyancy in Sand Casting Operation

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Other Expendable Mold Processes

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 11.5 Steps in shellmolding: (1) a matchplate or

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e

Advantages and Disadvantages

Expanded Polystyrene Process

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Expanded Polystyrene Process

Figure 11.7 Expanded polystyrene

Advantages and Disadvantages

Expanded Polystyrene Process

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Investment Casting (Lost Wax Process)

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 11.8 Steps in investment casting: (1) wax patterns are

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 11.8 Steps in investment casting: (5) the mold is held in an

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 11.8 Steps in investment casting: (7) the mold is

Figure 11 9 A onepiece compressor stator with 108

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Advantages and Disadvantages

Plaster Mold Casting

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Advantages and Disadvantages

Ceramic Mold Casting

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Permanent Mold Casting Processes

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

The Basic Permanent Mold Process

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Permanent Mold Casting

Figure 11.10 Steps in permanent mold casting: (1) mold is

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Permanent Mold Casting

Modern Manufacturing 3/e

Advantages and Limitations

Applications of Permanent Mold Casting