Metal casting

Classification of casting Processes

Casting processes can be classified into following FOUR categories: g p g g
1. Conventional Molding Processes Green Sand Molding
a) Green Sand Molding
b) Dry Sand Molding b) Dry Sand Molding
c) Flask less Molding
2. Chemical Sand Molding Processes
a) Shell Molding a) Shell Molding
b) Sodium Silicate Molding
c) Investment casting
d) No-Bake Molding
3. Permanent Mold Processes
a) Gravity Die casting
b) Low and High Pressure Die Casting
4. Special Casting Processes
a) Lost Wax
b) Ceramics Shell Molding
c) Evaporative Pattern Casting
d) Vacuum Sealed Molding
e) Centrifugal Casting
Pattern
Functions
Obtaining a shaped mold cavity for casting
Molding the gating system
Establishing the parting line
Making core prints
Establishing locating points
Minimizing the casting defects attributable to the
pattern p
Providing economy in molding.
Characteristics Wood Aluminium CastIron Polyurethane
Machinability E G F G Machinability E G F G
WearResistance P G E E
Strength P G E F Strength P G E F
Repairability E F G E
Corrosion E E P E Corrosion
Resistance
E E P E
E E ll t G G d F F i P P E - Excellent, G - Good, F - Fair, P - Poor
Patterns
Loose pattern Loose pattern
Match plate pattern
Cope and drag Pattern
Expendable patterns
1. Loose pattern
simplest least expensive type simplest, least expensive type
reusable pattern
also known as one-piece patterns or solid patterns
suited only for low-quantity production
generally used for experimental or prototypes
made either in one piece or in two pieces
gates and risers are cut by hand
2.Matchplatepattern
pattern is split and the two portions are fixed on the opposite sides of
a plate, called the match plate.
match plate confirms to the parting line of the mold match plate confirms to the parting line of the mold
size of the match plate corresponds to the size of the molding flask
used for moderate to high-volume production of small- and medium-
size castings size castings
considerable dimensional accuracy
3.CopeandDragpattern
cope and drag portions of a split pattern are mounted or integrally
cast on separate plates
used for high-volume production or for the production of large
castings
Pattern cost is higher than for match plate patterns
t t l ldi t ti b l total molding cost per casting may be lower
cope and drag impression is simultaneously made
PatternAllowances
Sh i k ll Shrinkageallowance
Machinefinishallowance
Draft allowance Draftallowance
Distortionallowance
Sh i k ll Shrinkage allowance
It is a correction for shrinkage of the metal
Shrinkage allowance is the amount the pattern be made larger than the Shrinkage allowance is the amount the pattern be made larger than the
casting to provide for contraction
Liquid shrinkage
Solidification shrinkage
Solid shrinkage
Pattern makers shrinkage rule is a special scale which is generally used in
foundries
Machinefinishallowance
The amount the dimensions on a casting is made oversize to Theamountthedimensionsonacastingismadeoversizeto
providestockformachining
Thisisinfluencedbythemetal,castingdesign,methodof
castingandcleaning
Draft allowance Draft allowance
Draftisthetaperallowedontheverticalfacesofapattern
foreasyremovalfrommold. y
Taperisgenerally1.5
o
providedforhandmolding
Machinedrawnpatternsrequires1
o
taper.
Distortion allowance
Largecasting(flatplates,domeorUshapedcasting)distortwhen
d d f f t tt producedfromaperfectpattern.
Totakecareofthisthepatternmaybeintentionallydistorted.
Sand molding
Drag half of mold made by hand. Drag is ready to be rolled over in
preparation for making the cope
Cope mold rammed up.
Procedure
Place the pattern on the molding board Place the pattern on the molding board.
The drag part of the molding flask is placed on the board
Dry facing sand or dust is sprinkled over the board and y g p
pattern to provide a non sticky layer.
Molding sand is then riddled in to cover the pattern with the
fi h h d i l l fill d fingers; then the drag is completely filled.
The sand is then compacted firmly in the drag by means of
hand rammers. The ramming must neither be too hard or hand rammers. The ramming must neither be too hard or
soft.
After the ramming is over, the excess sand is leveled off with
h b k k d a straight bar known as a strike rod.
With the help of vent rod, vent holes are made in the drag to
the full depth of the flask as well as to the pattern the full depth of the flask as well as to the pattern
to facilitate the removal of gases during pouring and
solidification.
Thefinisheddragflaskisnowrolledovertothebottomboard
exposing the pattern exposingthepattern.
Copehalfofthepatternisthenplacedoverthedragpattern
withthehelpoflocatingpins.Thecopeflaskonthe drag
is locatedaligningagainwiththehelpofpins
Thedrypartingsandissprinkled.
Asprue pinformakingthesprue passageislocatedatasmall p p g p p g
distancefromthepattern.Also,riserpin,ifrequired,is placed
atanappropriateplace.
Repeat the operations like filling ramming and venting Repeattheoperationslikefilling,rammingandventing.
Thesprue andriserpinsareremovedfirstandapouringbasin
isscoopedoutatthetoptopourtheliquidmetal.
h f h d d d d f Thenpatternfromthecopeanddragisremovedandfacing
sandintheformofpasteisappliedalloverthemoldcavity
andrunners.
Themoldisassembledandisreadyforpouring
Shell molding process Shell molding process
Advantages of shell molding
Much superior finish dimensional accuracy and consistency in Much superior finish, dimensional accuracy and consistency in
producing quality casting compared with even mechanized
green sand moulding. Shell molding process can accurately g g g p y
replicate even the fine pattern details and dimensions and
hence can be used for precision casting
Capital outlay on sand preparation plant is not essential.
Good utilization of space
Low sand to metal ratio Low sand to metal ratio
The mould is separated from the pattern without the need to
enlarge the cavity. g y
Only a small quantity of sand is used hence cheaper process.
Costly Zircon sand, which has better cooling characteristics
and lower thermal expansion than silica sand, can also be used
since the sand consumption is less.
Mould coating are unnecessary
Lightweight moulds are produced which are readily handled Lightweight moulds are produced which are readily handled
and have good storage characteristics
Skilled labor is not required q
Shells have excellent breakdown at the knockout stage
Lower cleaning at fettling costs
Disadvantages
The raw material are relatively expensive High cost of The raw material are relatively expensive. High cost of
pattern equipment and resin
Relative inflexibility in gating and risering as these have to y g g g
be provided in the shell itself.
The size and weight range of casting is limited
h i f hi h b The process generates noxious fumes which must be
effectively extract
Investmentcasting
InvestmentcastingProcess
1. Masterpattern
2 Mould making 2. Mouldmaking
3. Producingwaxpatterns
4. Waxpatternassembly
5. Investment
6. Dewax
7. Burnout&preheating
8. Pouring
9 Removal 9.Removal
Wax pattern
Finished Turbocharger Rotor
Investmentcasting
PLASTERMOULDING
The conventional plaster mould casting process.
The foamed plaster process.
The Antioch process The Antioch process
Conventional Plaster mold casting
Plaster of paris is mixed with water to produce a slurry.
Slurry is poured over a permanent pattern placed inside a moulding
box and allowed to set to form a rigid mold.
The pattern is stripped, and dried at an elevated temperature to
remove free and chemically combined water remove free and chemically combined water.
Molten metal is poured in to the mold and allowed to solidify.
The method produces a strong, dense, but inherently impermeable
mould..
Foam Plaster molding process
Plaster of paris is mixed with water to produce a slurry.
Air is incorporated in to the slurry during the mixing stage. p y g g g
The Slurry with air bubbles is poured on the permanent pattern
and allowed to set.
It is possible to produce a mould in which 50% of the volume
consists of air bubbles.
This increases the permeability from 1 or 2 units to between
15-30 units, as measured by the AFS permeability test.
The process provides the more economical use of the plaster The process provides the more economical use of the plaster.
However, the inherent strength of the mould is reduced and if
complex shapes are to be produced than flexible patterns complex shapes are to be produced than flexible patterns
traditionally rubber may be required.
Advantages of plaster molding
The ability to produce complex shapes The ability to produce complex shapes.
The ability to produce thin section castings.
The excellent replication of pattern detail.
The ability to produce castings which are dimensionally accurate.
The ability to produce castings with good surface finish.
The minimization of residual stresses and distortion in castings. g
Disadvantages
Poor productivity due to lengthy processing problems.
The need for multiple patterns to improve moulding productivity The need for multiple patterns to improve moulding productivity.
The requirement for close control production process.
The need for special procedure to overcome the problems of poor
mould permeability.
The possibility of impaired mechanical properties arising as a
result of slow cooling of the casting. g g
The mould materials are not reclaimable.
Permanent mold casting Permanentmoldcasting
LowpressurePermanentmold
(LPPM)process
Simplesplitpermanent
moldprocess
Truecentrifugalcasting
Semicentrifugalcasting
Highpressurediecasting
The dies prepared and assembled in the die casting machine.
Lubricant is sprayed on the mold cavity This is for easy
removal of the casting from the die as well as for controlling removal of the casting from the die as well as for controlling
the die temperature. The dies are then closed.
Molten metal is injected into the dies (till the mold cavity is
filled) under high pressure ( in the range 10 and 175 MPa).
The pressure injection leads to a quick filling of the die so
that the entire cavity fills before any part of the casting that the entire cavity fills before any part of the casting
solidifies The pressure is maintained until the casting
solidifies.
The dies are then opened and the shot solidified metal is
ejected by the ejector pins.
The casting is trimmed or sawed or ground to remove the The casting is trimmed or sawed or ground to remove the
scrap portion (like gate, runners, sprue, etc).
Ad t f hi h di ti Advantages of high pressure die casting
Excellent dimensional accuracy.
Smooth cast surfaces with Ra values in the range 12.5 m).
Thinner walls of the order of even 0.75 mm thick can be cast as
compared to sand and permanent mold casting. compared to sand and permanent mold casting.
Inserts such as threaded inserts, heating elements, high strength
bearing surfaces, etc. can be cast-in.
R d li i t d hi i ti Reduces or eliminates secondary machining operations.
Rapid production rates.
Due to pressure application, high solidification rate and absence of
gas defects, high strengths of the order of 400 MPa can be obtained
for castings.
Low fluidity metals can also be cast.. Low fluidity metals can also be cast..
Hot chamber die-casting
Initially the piston of the machine is retracted. This allows the molten metal y p
to flow and fill the cylinder up to the goose neck through the intake port ,
which allows the molten metal to fill the "gooseneck".
The externally powered piston then forces this metal out of the gooseneck
into the die and allow to solidify under pressure.
Cycle time is very fast (approximately 10-15cycles a minute).
Disadvantage
high-melting point metals cannot be
utilized.
Aluminium cannot be used because it
picks up some of the iron while in the
molten pool.
Used primarily for zinc, tin, and lead
based alloys
Hotchamberdiecasting
Coldchamberhighpressurediecasting
In cold chamber die casting the molten charge is ladled from a furnace In cold chamber die casting, the molten charge is ladled from a furnace
in to the shot sleeve of the machine. Normally more material than that
required for filling the cavity is taken. This is to supplement shrinkage
during solidification A hydraulically or pneumatically operated plunger during solidification. A hydraulically or pneumatically operated plunger
pushes the metal in to the die under a pressure of up to 70 MPa till
solidification is complete.
High volume cost-effective production with consistent quality
Eliminating costly post-casting operations. Hence reduced cost
Easily manufacture complex Net shaped parts with tight tolerances Easily manufacture complex Net shaped parts with tight tolerances
Lower tool cost and longer tool life
Lowest total acquisition cost
Cold Chamber diecasting ColdChamberdie casting
Continuouscastingprocess
Continuous casting process
Molten metal from the furnace is transferred in to ladle.
The ladle is transported to the top of the continuous casting machine.
Hot metal is transferred from ladle to a Tundish.
Molten metal from the tundish is fed continuously from the top into a
water cooled copper mold where it solidifies while in contact with the
mold (primary solidification). mold (primary solidification).
A thin shell of molten metal in contact with the mold solidifies.
Solidified metal is pulled out of the mold at a constant pull velocity.
The mold oscillation is provided to prevent the metal sticking to the mold The mold oscillation is provided to prevent the metal sticking to the mold.
The partially solidified metal is allowed to solidify while moving through a
series of water sprays.
The uninterrupted supply of the molten metal at the mold inlet and mold The uninterrupted supply of the molten metal at the mold inlet and mold
exit leads to a continuous production of slabs or billets.
After complete solidification , the strand passes through straightening
rolls and withdrawal rolls rolls and withdrawal rolls.
Finally, the strand is cut into predetermined lengths by mechanical
shears or by travelling oxyacetylene torches.