Zainudin Yahya: Office: BN-Block, Level-3, Room-055 Email: Zai@uniten - Edu.my Ext. No.: 2241 H/P No.: 0122669986

ZAINUDIN YAHYA
Office: BN-Block, Level-3,

Room-055
Email: zai@uniten.edu.my
Ext. No.: 2241
H/P No.: 0122669986
University TENAGA Lecturer: ZAINUDIN YAHYA
National - MALAYSIA
Foundry Process
Foundry Processes

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Foundry:
Is a process of producing metal castings.
Foundry process
consist of:
1 4
Making moulds Cleaning the
casting
2 3
Melting the metal Pouring liquid metal
in to the mould
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Making moulds
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Foundry Process
Melting the metal & Pouring liquid metal in to the mould

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Casting processes are required to approach
the required shape of the part
Casting
Casting:
Is an operation of shaping metal by pouring
it in the liquid state into a mold followed by
solidification.
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Classification of Moulds
1 Sand moulds
2 Metal moulds
3 Plaster moulds
4 Ceramic moulds

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Sand Casting and Molding
Procedure
Sand casting are very famous because of

Their economic advantages. Sand moulds
produce Cheap casting

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(According to the Pattern Type
1 Removable Pattern
2 Disposable Pattern

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Removable Pattern
Sand is packed around the pattern. After
that a cavity will be formed by removing the
pattern. The molten metal is poured in to
cavity.
Patterns are made of wood (Inexpensive,
Easily work). Patterns are coated with
varnish to create good smooth surfaces.
In case of mass production metal patterns
Are used. Materials for metal patterns:
Brass, Al, Cast iron, Plastic.
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Cont….. Removable Pattern
Loose-pieces patterns are used when it is

possible for a single piece pattern to be
Withdrawn from the mould because of its
overhanging surfaces. A pattern is divided
into a main pattern and several other loose
pieces attached to the main piece by pins.
The loose pieces are removed separately
After withdrawing the main pattern.

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Removable Pattern
a b c
Wooden - Pattern

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Removable Pattern
Metal - Pattern
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Steps of making removable pattern moulds
1)Making the drag:The pattern (or half pattern)

is placed on a moulding sand is rammed
around the pattern. The sand is vibrated so
it falls down on the pattern. The sand then
is pressed. The drag is turned over and a
gate to the cavity is formed.

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Cont….. Steps of making removable pattern moulds
2)Making the cope: Using the same steps for

the drag but in addition the sprue pin is
built in. The cope then is turned over and
put on the drag. Small vents are formed
through the sand to ensure the escapes
of gases.

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Disposable Pattern
Patterns are made from polystyrene. Sand is
packed around the pattern. The pattern is not
removed but it is vaporized when the molten
metal is poured into the mould.
Usually one pattern is made ( it includes

Sprue, gate and risers). The pattern is placed
on the board within the drag. Then the drag
Is turned over for moulding the cope.
Pattern material: Polystyrene.
Moulding material: Green sand.
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Cont….. Disposable Pattern
1- Sample- Disposable Pattern

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There are two operations to produce the

disposable patterns:
1)Hand making: Patterns may glued and hot
wire or hot knife curved. Sprues, gates, and
risers may be attached by glue or nails.
2)Using a metal : Polystyrene is filled in to a

mould in order to form the pattern shape.
* Used for complex shapes.
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Advantage for disposable pattern

1 Less production time.
2 Smooth and uniform castings
3 No need for complicated patterns
Simple moulding process. No need for
4 highly skilled people
No allowances required for removing

5 the pattern
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Disadvantage for disposable pattern

1 Easily broken patters
Patterns are destroyed (An additional
2
needed to form the patterns)..
No opportunity to check the finished

3
cavity before pouring.
Environmental concerns because of

4
the poisonous gases.
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(According to Molding Material)
1 Green sand moulds
2 Loam moulds
3 Furfuryl alcohol binder moulds
4 CO2 Moulds
5 Skin dried moulds
6 Dry sand moulds
7 Metal and special Moulds
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1- Green sand moulds
The sand color is not green, but it is called

green because clay or water is used for
boding
2- Loam moulds
Loam = a loose soil of mixed clay and sand.
These moulds are used for large casting.
The mould first is built up with bricks. These
bricks are covered with thick loam. These
moulds are seldom used because they
Require a long time to prepared.
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3- Green
Furfuryl alcohol
sand binder moulds
moulds
Furan is the trade mark of this mould. The
mould uses disposable patterns. Molding
material: Dry sand, Phosphoric, Sulphuric
acid, and furan resin.
4- CO2 moulds
Molding material: Sand, Sodium silicate.

CO2 is used to make the sand mixture hard.
Advantage: Smooth casting.
Disadvantage: Difficult shakeout and core
Removal.
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5-Skin
Greendried
sandmoulds
moulds
A mixture of sand and binder is packed to a
depth of ½ in around the pattern. Then it left
to dry and a hard surface around the pattern
is formed. The remainder of the mould is
common sand.
6- Dry sand moulds
Molding material: Common sand, a binder.

The mould is backed in a oven before using.
Advantage: Simple, free of gases caused by
Moisture.
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7-Metal
Greenand special
sand mouldsmoulds
Metal moulds are used to die cast,

Low-melting-temperature alloys (Al, Zinc,
and copper).
Advantage: Smooth casting, accurate shape,
Eliminate some machining processes.

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Classification of Molding Processes:
1)Bench molding: It is used for small casting
The molding work is done on a bench at
high convenient to the worker, (Molder).
2)Floor molding: For medium-size and large

casting. The work is done in the floor.
(Easy for the molder to operate).
3)Pit molding: For extremely large casting.

Pit = A hole, room built in the ground.
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Cont---
4)Machine molding: Moulds are replaced by

automatic molding machine (ramming the
sand, forming the gates, removing patterns
and cores.

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Gating Systems and
Solidification Characteristics
Gating system: Is the passageway that

brings the molten metal into the cavity.
Gating system consists of:

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Cont---
1 Pouring basin
2 Down gate or vertical channel (Sprue)
3 Gate
-Molten metal should not pull away

when it is poured downward. So we
have to design a taper (Sprue) that
allows the metal to fall freely.
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Cont---
A1 / A2 ≤ (ha / hb )1/2
A1 / A2 – Cross-Sectional areas of the

entrance and exit locations of the
sprue, m2
Ha – Head of metal of pouring basin,
Hb – Head of metal of pouring basin +

Sprue.
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A1
Ha
Hb
A2

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Cont---
-The following factor should be

considered when gating system is
designed:
1 Turbulence should be reduced at the

bottom cavity (Solution: Basin)
Erosion (wearing away) should be

2
avoided by regulating the flow of metal
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Cont---
Metal should enter the cavity in such

away that solidification starts from
3 the mould surface to the hottest
metal (Near the gate).
Slag and foreign particles should be

prevented from the entering mould
4 cavity (Solution: A basin near the
entrance of the sprue).

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Risers:
Objectives:
• To feed molten metal in to the cavity in
order to compensate for shrinkage.
Risers should be last to solidify.
• Solidification should be controlled in such

a way that voids caused by shrinkage are
created only in the gating system and
raisers.
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Patterns: (Types)
1 Solid patterns: They are the simplest

and used when it is easy to remove them.
2
Split patterns: Used when casting has
a complex shape.
3
Loose-piece patterns: To facilitate
the pattern removal.
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Cont---
4 Gated patterns: To increase produc-

tion (several casting in one mould).
5 Match plates: Used for mounting

patterns.
6 Follow boards: Used for patterns that

cannot be made as a split pattern.

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Allowances
Allowances are added to the patterns
Because of some (Shrinkage, draft,
Machining, and distortion)
1
Shrinkage allowance: Used to
Compensate for shrinkage.
Draft allowance: Is tapering the

2
vertical sides of the pattern so it will easy
To withdraw the pattern.
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Cont---
Finish allowance: When surface in

3 the design drawing has a finish mark such
as ( ). So some allowance for machining
Should be added.
distortion allowance: Should be

4
Added because the shape of a casting is
Distorted when the metal solidifies .

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Cont---
Shake allowance: The pattern is

Made slightly smaller by applying a shake
5 allowance because when a pattern is
rapped in the mould and withdrawn after
that, the cavity in the mould increases
Slightly

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Sand technology (SiO2):
Advantages: Withstand high tempera-
ture, inexpensive, long life, wide range of
grain sizes.
Disadvantages: Has a high expansion
rate when it is heated, fuses with the molten
metal.
Clay is added to the pure silica sand to form

binding qualities.
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Cont--- Sand technology (SiO2):
With intricate and small castings a fine and

is desirable and with large castings a sand
With big grains is used.
After using the foundry sand for along time

some tests should be held to check the
following Properties:
1- Permeability: Porosity enables the gases
to escape.
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Cont--- Sand technology (SiO2):
2- Strength: Sand must have sufficient bond.
3- Refractoriness: Sand must not fuse with

High temperatures.
4- Grain size and shape: The grain size must

be suitable for the desired casting surface
and the shape must be irregular to permit
Interlocking.
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Test for foundry processes
1- Mould and core Hardness Test:
A steel ball is pressed into the mould surface
From the depth of penetration we can decide
on the mould hardness and firmness.
2- Fineness Test:
The percentage distribution of grain sizes is
Determined using standard sieves . The
Mashes are 6,12,20,30,40,50,70,100,140,200,
270.
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Cont--- Test for foundry processes
3- Moisture content Test:

The moisture content should vary from 2% to
8%, depending on the type of moulding.
4- Clay content Test:
The moisture content should vary from 2% to
8%, depending on the type of moulding.
5- permeability Test:
This test determines the level of the sand
Porosity. Permeability is measured by the
Quantity of air that passes through a sample
of sand in prescribed time and under
standard
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Lecturer: ZAINUDIN YAHYA
Cont--- Test for foundry processes
6- Strength Test:

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Sand Conditioning
The molding mixture must have the following

results after conditioning or reconditioning:
1- Description uniformity of the binder.

2- Controlled moisture.
3- No foreign particles.
4- Sand is cooled.
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Cont--- Sand conditioning
Example:
Foundry unit for reconditioning foundry sand.
Figure – Page - 91

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Cores
A core is a special pattern that is used to

form a cavity in the casting. Cores are
inserted separately into the mould after
removing the pattern and it remains in the
Mould. Internal external surface can be
Formed by cores.

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Green dry sand cores
The same sand used for moulding is also
Used for making cores.
Green sand cores are formed by the
Pattern the Figure as shown in the next
Slide. They are less expensive than dry
sand cores.
Dry sand cores are inserted separately
Into the mould after removing the pattern
And it remains in the mould. cores are
produced
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in core boxes.
Cont--- Green dry Sand cores

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Cont--- Green dry Sand cores
Advantages: Dry sand cores give

Smooth casting surfaces and cannot be
Easily washed away by the flow of molten
Metal.
Cores must:
1- Have sufficient strength .
2- Have good porosity for the gases to
escape .
3- Have a smooth surface to ensure
smooth
University TENAGA
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Cont--- Cores must
4- Resist the action of the heat .
Cores making:
(Hand making) Sand is rammed into a core
Box, cores are reinforced with wires to add
Strength.
(Using machines) Example: Core-blowing
Machine: Sand is blown under pressure and
with high velocity from a sand magazine
Into
Universitythe core
TENAGA
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box:
Cont--- Cores making

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Moulding equipment:
1-Jolt-moulding machine principle:
The mould is put on the machine table. The

Table is pneumatically raised and dropped.
Result: the sand is packed evenly around
The pattern with high density.

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Jolt-moulding machine

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Cont--- Moulding equipment
2-Sequeezer machine:
- It simply presses the sand.
Disadvantage: Impossible to obtain uniform

density of the sand.
Other type of machine can used metal
mould.

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Squeeze Casting Mach.
(c) Close die and
apply pressure
(a) Melt Metal

(d) Eject squeeze
casting and
charge melt
stock and repeat
cycle
Sequence of operations in the squeeze-casting

process. This process combines the advantages
(b) Pour molten
metal into die
of casting and forging.
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3-Sand slinger:

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4- Diaphragm moulding machine:
-A pure gum rubber is used to ram the sand

around the pattern
Advantage: Uniform density of sand.

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Diaphragm
Flask under head

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Pouring and cleaning casting
The foundry Cleaning Room is collection processes
where castings are ‘finished’ to meet the customers
specifications.
A sample flow chart is shown below for one type of

steel casting. Many alternate casting workflows exist
as part of ISO 9002 program. This insures that
castings are made and finished to the customer’s
specifications and standard industry practices.

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Cont--- Pouring and cleaning casting
When castings are removed from the shakeout, they

are run through the shot blast to remove sand and
expose the surface for inspection and further work
. The next step is the removal of the gating system.

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University TENAGA Cleaning Flowchart

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Sand Blast Machine

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Products after Sand Blasting

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To pour molten metal into a mold a path is required

called a ‘pouring sprue’. The pouring sprue will
generally will have many feeders to various parts of
the casting. This is called the ‘gating system’.
In addition, as metal shrinks while it is cooling, so

additional pockets of molten metal, called ‘ risers’,
must be present to feed into the casting. Once the
pouring sprue, risers, and gates are removed in the
‘Burn & Arc’ areas, the castings are returned to the
shot blast to be cleaned for inspection( Flowchart).
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At the first inspection, castings are inspected for

defects such as cracks, flashing, inclusions, etc. If
none are found the castings are sent to the Heat
Treating department. If defects are present that
require welding and/or grinding the castings are
sent to the appropriate area to have the defect
corrected. Once rework is completed, the castings
are sent to the Heat Treating department.

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After being heat treated, The castings are again

sent through the shot blast before being sent to the
Final Inspection area.
If a casting fails the Final Inspection it may be

returned for rework or sent to the scrap bin for re-melt
if the defect is severe. When castings pass
inspection they are sent to the shipping dock and
the production department notified so that the
necessary paperwork can be processed.

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Next Lecture:
Continue in Foundry
Processes and
Contemporary casting
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THANK YOU
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Zainudin Yahya: Office: BN-Block, Level-3, Room-055 Email: Zai@uniten - Edu.my Ext. No.: 2241 H/P No.: 0122669986

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ZAINUDIN YAHYA

Office: BN-Block, Level-3,

University TENAGA Lecturer: ZAINUDIN YAHYA

Melting the metal & Pouring liquid metal in to the mould

University TENAGA Lecturer: ZAINUDIN YAHYA

Sand casting are very famous because of

University TENAGA Lecturer: ZAINUDIN YAHYA

University TENAGA Lecturer: ZAINUDIN YAHYA

Loose-pieces patterns are used when it is

University TENAGA Lecturer: ZAINUDIN YAHYA

University TENAGA Lecturer: ZAINUDIN YAHYA

1)Making the drag:The pattern (or half pattern)

University TENAGA Lecturer: ZAINUDIN YAHYA

2)Making the cope: Using the same steps for

University TENAGA Lecturer: ZAINUDIN YAHYA

Usually one pattern is made ( it includes

1- Sample- Disposable Pattern

There are two operations to produce the

2)Using a metal : Polystyrene is filled in to a

Advantage for disposable pattern

No allowances required for removing

Disadvantage for disposable pattern

No opportunity to check the finished

Environmental concerns because of

The sand color is not green, but it is called

Molding material: Sand, Sodium silicate.

Molding material: Common sand, a binder.

Metal moulds are used to die cast,

University TENAGA Lecturer: ZAINUDIN YAHYA

2)Floor molding: For medium-size and large

3)Pit molding: For extremely large casting.

4)Machine molding: Moulds are replaced by

University TENAGA Lecturer: ZAINUDIN YAHYA

Gating system: Is the passageway that

University TENAGA Lecturer: ZAINUDIN YAHYA

2 Down gate or vertical channel (Sprue)

-Molten metal should not pull away

A1 / A2 – Cross-Sectional areas of the

Ha – Head of metal of pouring basin,

Hb – Head of metal of pouring basin +

University TENAGA Lecturer: ZAINUDIN YAHYA

-The following factor should be

1 Turbulence should be reduced at the

Erosion (wearing away) should be

Metal should enter the cavity in such

Slag and foreign particles should be

University TENAGA Lecturer: ZAINUDIN YAHYA

• Solidification should be controlled in such

1 Solid patterns: They are the simplest

4 Gated patterns: To increase produc-

5 Match plates: Used for mounting

6 Follow boards: Used for patterns that

University TENAGA Lecturer: ZAINUDIN YAHYA

Draft allowance: Is tapering the

Finish allowance: When surface in

distortion allowance: Should be

University TENAGA Lecturer: ZAINUDIN YAHYA

Shake allowance: The pattern is

University TENAGA Lecturer: ZAINUDIN YAHYA

Clay is added to the pure silica sand to form

With intricate and small castings a fine and

After using the foundry sand for along time

2- Strength: Sand must have sufficient bond.