Mech Zone

Casting
Process Part 1
(SSC JE Mechanical/ GATE/ONGC/SAIL
BHEL/HPCL/IOCL)
 Refractory mold  pour liquid metal  solidify, remove  finish

Casting - Process of Producing Metallic Parts by Pouring

Molten Metal in to a Mould having a Cavity of the Part to
be Cast and then Allowing the Molten Metal to Solidify.
Moulding – Process of Making a Mould Using a Pattern.
Pattern – A Model or Replica of the Part to be Cast.
Advantages
• Complex forms, low cost
• Certain shapes cannot be machined
• One piece parts vs. multiple piece parts
• Design changes are easily incorporated
• High volume, low skilled labor
• Large, heavy parts can be made easily

Disadvantages
• Problems with internal porosity
• Dimensional variations due to
shrinkage
• Trapped impurities, solids and gasses
• High-tolerance, smooth surfaces not
possible
• More costly than stamping or
extruding in some cases
• Sand Mould Casting – Molten Metal is Poured into the
Cavity of the Mould without Applying External
Pressure (Gravity Feed).
• Permanent Mould Casting - Gravity Die Casting
• Die Casting – Molten Metal is Forced under very high
Pressure in to the Die (Metallic Mould).
– Hot Chamber Die Casting
– Cold Chamber Die Casting
 Forms of Casting and Terminology

Flask : The box containing the mold

Cope : The top half of any part of a 2-part mold
Drag : The bottom half of any part of a 2-part mold
Core: A shape inserted into the mold to form internal cavities
Core Print : A region used to support the core
Mold Cavity: The hollow mold area in which metal solidifies into the part
Riser: An extra cavity to store additional metal to prevent shrinkage
Gating System: Channels used to deliver metal into the mold cavity
Pouring Cup: The part of the gating system that receives poured metal
Sprue: Vertical channel
Runners: Horizontal channels
Parting Line / Parting Surface: Interface that separates the cope and drag of a 2-part mold
Draft: Taper on a pattern or casting that allows removal from the mold
Core Box: Mold or die used to produce cores
Casting: The process and product of solidifying metal in a mold

Metal Solidification
 Metal Solidification

Dendrites
Tree-like structures that form during the solidification of alloys

Slow cooling rates produce dendrites with larger branch spacing;

faster cooling rates produce finer spacing; very fast cooling rates
produce no dendrites or grains
 Shrinkage or Contraction

Tp
Liquid shrinkage

Tf solidification shrinkage

solid shrinkage

Ta
 Fluid Flow
Metal is poured through a pouring cup

Risers hold and supply metal to prevent shrinking

during solidification

Gates are designed to prevent contaminants from

reaching the mold cavity
 Fluidity of Molten Metal
Fluidity
The capability of a molten metal to fill mold cavities

Viscosity
Higher viscosity decreases fluidity

Surface tension
Decreases fluidity; often caused by oxide film

Inclusions
Insoluble particles can increase viscosity, reducing fluidity

Solidification pattern
Fluidity is inversely proportional to the freezing temperature
range
 Fluidity of Molten Metal

Heat Transfer
• The metal that solidifies first is at the wall of the mold; this solid layer thickens
as time passes
• Shrinkage during cooling can change the part dimensions and sometimes cause
cracking; it is caused by the metal’s thermal expansion properties and the
phase change between liquid and solid.
 Classification of Casting Processes
Process Advantages Disadvantages Examples
Sand many metals, sizes, shapes, poor finish & engine blocks,
cheap tolerance cylinder heads
Shell mold better accuracy, finish, higher limited part size connecting rods,
production rate gear housings
Expendable Wide range of metals, sizes, patterns have low cylinder heads,
pattern shapes strength brake components
Plaster mold complex shapes, good surface non-ferrous metals, prototypes of
finish low production rate mechanical parts
Ceramic mold complex shapes, high accuracy, small sizes impellers, injection
good finish mold tooling
Investment complex shapes, excellent finish small parts, expensive jewellery

Permanent good finish, low porosity, high Costly mold, simpler gears, gear
mold production rate shapes only housings
Die Excellent dimensional accuracy, costly dies, small gears, camera
high production rate parts, bodies, car wheels
non-ferrous metals
Centrifugal Large cylindrical parts, good Expensive, few shapes pipes, boilers,
quality flywheels
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Mech Zone…
(SSC JE Mechanical/ GATE/ONGC/SAIL
BHEL/HPCL/IOCL)
Mech Zone 16