Casting-01

Different type Furnaces

Different casting process

Cupola Furnace

Electric Arc Furnace (Open-hearth)

Crucible Furnace

Induction Furnace

Ladles

Casting Defects
Gas defects

Blowholes and open blows

Air inclusion
Pinhole porosity
Shrinkage cavities

Moulding material defects

Cuts and wash

Metal penetration
Fusion
Run-out
Rat Tail
Drop

Pouring metal defects

Misrun and cold shut
Slag inclusion

Hot tear /Hot spot

Shell Mould casting

Advantages:

Dimensionally more accurate

Smoother surface is possible
Lower draft angle is required
Thin section can be casted
Small sand is required

Limitation:

Limited size of the casting (upto 200 kg)

Pattern are expensive ; useful for large-scale production (15000 pcs)
Higly complicated shape can not be cast
Sophisticated equipment required for handling the hot pattern

Application:
Cylinder and cylinder head of IC engine, Automobile parts, cast tooth bevel gear,
break beam, chain seat bracket, small crank shaft

Investment casting

Advantages:

Complex shapes can be produce (pattern is withdrawn by melting)

Very fine and thin section can be produce
Better surface finish and high accuracy
Ready for machining with low or very little machining
Mechanical properties of the product is maintained

Limitation:
Limited to size an mass of the casting (5 kg)
Expensive process

Application:
Old day art-craft, Surgical instrument, jewelry
Vanes and blades of turbine, waveguide for radar, stainless steel valve

Permanent mould casting

Advantages:

As metallic mould used fine grained casting with better mechanical properties
Good surface finish
Close dimensional tolerance
Economical for large scale production
Small core hole can be produce

Limitation:

Maximum size of the casting is limited

Very complicated shape can not be produce
Cost of die is very
Not all type of materials are suited for this process

Application:
Automobile piston, gear blanks, connecting rods, Cylinder blocks etc.

Die casting

Advantages:
For use of movable core complex casting is possible
Very thin section can be filled by injected pressure
High production rate (200 pc/Hr)
High quality surface finish
Closer dimensional tolerance
Long life of die can make 200,000-300,000 pieces casting
Economical for large scale production
Limitation:
Maximum size of the casting is limited
Sometimes air in the die cavity trapped
Cost of die is very high and
Not suitable for all type of materials
Application:
Carburetors, crank cases, automobile parts

 Centrifugal casting
Continuous casting
Slush casting