CHAPTER 12

Metal Casting: Design, Materials, and

Economics

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-1
 Casting Design Modifications

Figure 12.1 Suggested design

modifications to avoid defects
in castings. Note that sharp
corners are avoided to reduce
stress concentrations.
Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-2
 Casting Cross-Sections

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and Examples
Figure 12.2 reduction ofof designs
area in tension.
showingNote also that even
the importance within the same
of maintaining group,
uniform the sections
cross- properties
in of cast
alloys varytoover
castings a wide
avoid range,and
hot spots particularly
shrinkagefor cast steels. Source: Steel Founders' Society of America.
cavities.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-3
 Avoiding Shrinkage Cavities

Figure 12.3 Examples of

design modifications to avoid
shrinkage cavities in castings.
Source: Steel Castings
Handbook, 5th ed. Steel
Founders' Society of America,
1980. Used with permission.

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

Kalpakjian Schmid
Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-4
 Chills

Figure 12.4 The use of

metal padding (chills) to
increase the rate of cooling
in thick regions in a casting
to avoid shrinkage cavities.
Source: Steel Castings
Handbook, 5th ed. Steel
Founders' Society of
America, 1980. Used with
permission.

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-5
 Normal Shrinkage Allowance for Some Metals
Cast in Sand Molds

TABLE 12.1
Metal Percent
Gray cast iron White 0.831.3
cast iron Malleable 2.1
cast iron Aluminum 0.781.0
alloys Magnesium 1.3
alloys Yellow brass 1.3
Phosphor bronze 1.31.6
Aluminum bronze 1.01.6
High-manganese steel 2.1
2.6
Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-6
 Parting Line

Figure 12.5 Redesign of a

casting by making the parting
line straight to avoid defects.
Source: Steel Casting
Handbook, 5th ed. Steel
Founders' Society of America,
1980. Used with permission.

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-7
 Figure 12.6
Examples of
casting design
modifications.
Source: Steel
Casting
Handbook, 5th
ed. Steel
Founders'
Society of
America, 1980.
Used with
permission.

Casting Design
Modifications

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-8
 Desirable and Undesirable Die-Casting
Practices
Figure 12.7 Examples of
undesirable and desirable design
practices for die-cast parts. Note
that section-thickness uniformity is
maintained throughout the part.
Source: American Die Casting
Institute.

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-9
 Mechanical Properties for Various Groups of
Cast Alloys

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-10
 Mechanical Properties for Various Groups of
Cast Alloys (cont.)

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of cast
alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.

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Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-11
 Typical Applications for Casting and Casting
Characteristics
TABLE 12.2
Type of alloy Application Castability* Weldability* Machinability*
Aluminum Pistons, clutch housings, intake E F GE
manifolds
Copper Pumps, valves, gear blanks, marine FG F FG
propellers Crankshafts, heavy-duty
Ductile iron gears G D G
Gray iron Engine blocks, gears, brake disks E D G
and drums, machine bases
Magnesium Crankcase, transmission housings GE G E
Malleable iron Farm and construction machinery, G D G
heavy-duty bearings, railroad
rolling stock
Nickel Gas turbine blades, pump and valve F F F
components for chemical plants
Die blocks, heavy-duty gear
Steel (carbon and blanks, aircraft undercarriage F E F
low alloy) members, rail-road wheels
Gas turbine housings, pump and
Steel (high alloy) valve components, rock crusher F E F
jaws
Mill liners, shot blasting nozzles,
White iron railroad brake shoes, crushers and G VP VP
pulverizers
Door handles, radiator grills,
Zinc E D E
*E, excellent; G, good; F, fair; VP, very poor; D, difficult.

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 Properties and Typical Applications of Cast Irons
TABLE 12.3

Ultimate
tensile Yield Elongation
strength strength in 50 mm
Cast iron Type (MPa) (MPa) (%) Typical applications
Gray Ferritic 170 140 0.4 Pipe, sanitary ware
Pearlitic 275 240 0.4 Engine blocks, machine tools
Martensitic 550 550 0 Wearing surfaces
Ductile Ferritic 415 275 18 Pipe, general service
(Nodular) Pearlitic 550 380 6 Crankshafts, highly stressed parts
Tempered 825 620 2 High-strength machine parts,wear-resistant
martensite parts
Malleable Ferritic 365 240 18 Hardware, pipe fittings, general engineering
service
Pearlitic 450 310 10 Railroad equipment, couplings
Tempered 700 550 2 Railroad equipment, gears, connecting rods
martensite
White Pearlitic 275 275 0 Wear-resistant parts, mill rolls

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 Mechanical Properties of Gray Cast Irons

TABLE 12.4
Ultimate
tensile Compressive Elastic
ASTM strength strength modulus Hardness
class (MPa) (MPa) (GPa) (HB)
20 152 572 66 to 97 156
25 179 669 79 to 102 174
30 214 752 90 to 113 210
35 252 855 100 to 119 212
40 293 965 110 to 138 235
50 362 1130 130 to 157 262
60 431 1293 141 to 162 302

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 Properties and Typical Applications of Cast
Nonferrous Alloys
TABLE 12.5
Ultimate
tensile Yield Elongation
strength strength in 50 mm
Alloys (UNS) Condition (MPa) (MPa) (%) Typical applications
Aluminum alloys 195 Sand castings Sand
(AO1950) Heat treated 220280 110220 8.52 castings
319 (AO3190) Heat treated 185250 125180 21.5 Permanent mold castings
356 (AO3560) Heat treated 260 185 5
Copper alloys
Red brass (C83600) Annealed 235 115 25 Pipe fittings, gears
Yellow brass (C86400) Annealed 275 95 25 Hardware, ornamental
Manganese bronze Annealed 480 195 30 Propeller hubs, blades
(C86100)
Leaded tin bronze Annealed 260 105 35 Gears, bearings, valves
(C92500)
Gun metal (C90500) Annealed 275 105 30 Pump parts, fittings
Nickel silver (C97600) Annealed 275 175 15 Marine parts, valves
Magnesium alloys
AZ91A AZ63A F 230 150 3 Die castings
T4 275 95 12 Sand and permanent mold
castings
AZ91C T6 275 130 5 High strength Elevated
EZ33A T5 160 110 3 temperature
HK31A T6 210 105 8 Elevated temperature
QE22A T6 275 205 4 Highest strength

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 General Cost Characteristics of Casting
Processes
TABLE 12.6
Cost*
Production
Process Die Equipment Labor rate (Pc/hr)
Sand L L L LM <20
Shell-mold M M-H LM <50
Plaster LM M MH <10
Investment MH L- H L <1000
Permanent mold MH MM M <60
Die M HH LM <200
Centrifugal LM <50
* L, low; M, medium; H, high.

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