NITC

Some basics - you had in Foundry

Sand casting.
Steps:

1.Mechanical Drawing of the part

2. Making pattern- about pattern material.
3.Making cores- if needed
4.Preparing drag and cope. (Setting the core, positioning etc.)
5.Removal of pattern
6Assembling cope and drag
7.Pouring- factors, method, etc.
8.Casting removed
9.Trimming etc.
10. READY FOR SHIPMENT
NITC

Some basics you had

in Foundry
1.Mechanical Drawing of the part
1

3a

2. Making pattern- about pattern

material.
3.Making cores- if needed

3c

3b

4.Preparing drag and cope.

(Setting the core, positioning etc.)
4b

4a

5a

5.Removal of pattern
6Assembling cope and drag

5b

8&9

10

7.Pouring- factors, method, etc.

8.Casting removed

CASTING
Basically involves

FUNDAMENTALS

i. Pouring molten metal into a mould patterned after the part to be made
WITHOUT TURBULANCE , SERIES OF EVENTS TAKES PLACE
INFLUENCE SIZE, SHAPE, UNIFORMITY OF THE GRAINS FORMED,
AND THUS THE OVERALL PROPERTIES.

ii. Allow it to cool

HEAT TRANSFER DURING SOLIDIFICATION

iii. Remove from the mold

INFLUENCE OF THE TYPE OF MOULD MATERIAL

SIMILARITY WITH POURING CAKE MIX INTO A PAN

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POURING CAKE MIX INTO A PAN (MOULD) & BAKING IT

*SELECT THE KIND AND SIZE OF PAN,
*CONTROL THE COMPOSITION OF THE MIX,
* CAREFULLY POUR THE MIX,
* SET THE PROPER BAKING TEMPERATURE,
* SET THE TIMER FOR PROPER BAKING TIME,
* LEAVE THE CAKE IN THE MOULD FOR A CERTAIN
AMOUNT OF TIME BEFORE REMOVING.
(CASTING OF PLASTICS & CERAMICS - DIFFERENT)
NITC

Knowledge of certain fundamental relationships

is essential to produce good quality economic
castings
This knowledge helps in establishing proper
techniques for mould design and casting practice.
Castings must be free from defects, must meet the
required strength, dimensional accuracy, surface
finish
NITC

Moulding

Sand

- pattern making
- Core making
- Gating system

Mould

Melting Pouring

casting Heat Treat

Furnaces Solidification

Shakeout

Clean

Inspect

Addl. Heat Treatment

Defects, pressure tightness, dimensions

Outline of production steps in a typical sand casting operation NITC

NIT CALICUT

ADVANTAGES OF CASTING PROCESS

Process is cheap
More suitable for mass production
Most suitable for manufacturing
complex/complicated/intricate shaped products.
Large parts weighing several tonnes and also small
components weighing a few grams can be cast.
No limitation on the size of component.
Directional properties absent in castings. Components with
uniform properties as well as with varying properties at
different locations can be cast.
By use of cores, saving in machining of holes achieved.
Internal stresses are relieved during solidification in many
types of castings.
Even some materials which cannot be made by other
processes made by casting: eg. Phosphor-Bronze.

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NIT CALICUT

DISADVANTAGES
Cast product properties inferior in many
cases when compared with other
manufacturing processes.
Elevated temperature working in
castings, as material has to be melted.
Thin section limitations exist.
For number of components very small,
casting not preferred.

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SIGNIFICANT FACTORSTYPE OF METAL,

THERMAL PROPERTIES OF BOTH THE METAL
AND MOULD,
GEOMETRIC RELATIONSHIP BETWEEN THE
VOLUME AND SURFACE AREA ,AND
SHAPE OF MOULD.
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 SOLIDIFICATION OF METALS
AFTER POURING MOLTEN METAL INTO
MOULD, SERIES OF EVENTS TAKES
PLACE DURING SOLIDIFICATION AND
COOLING TO AMBIENT TEMPERATURE.
THESE EVENTS GREATLY INFLUENCE
THE SIZE, SHAPE, UNIFORMITY OF THE
GRAINS FORMED, AND THUS THE
OVERALLL PROPERTIES.
NITC

Volumetric variation from Liquid through

Solidification and then to ambient temperature

Three Stages of Contraction (Shrinkage)

The liquid Metal has a Volume

"A

It solidifies to solid with a new

volume "B"

COOLING CURVE
For pure metal or compound
T
E
M
P
E
R
A
T
U
R
E

Cooling
of Liquid
Freezing begins

Freezing ends

At constant
temperature
Cooling of solid

Liquid
Liquid

+
Solid

TIME, log scale

Latent heat of
solidification
given off
during
freezing-

Solid

COOLING CURVE
For Binary solid solutions
T
E
M
P
E
R
A
T
U
R
E

Freezing with drop in

temperature

And FOR ALLOYS:

Alloys solidify over a range of
temperatures
Begins when temp. drops below
liquidous, completed when it
reaches solidous.
Within this temperature range,
mushy or pasty state.
Inner zone can be extended
throughout by adding a catalyst.sodium, bismuth, tellurium, Mg
(or by eliminating thermal
gradient, i.e. eliminating
convection. (Expts in space to
see the effect of lack of gravity in
eliminating convection)

TIME, log scale

(refresh dendritic growthbranches of tree, interlock, each

dendrite develops uniform
composition, etc)

The ambient
temperature is
always in a state of
transition
Minor variations in
volumetric
displacement are
negligible,
compared to the
variations that occur
from "A" to "B" and
lastly to "C".

*
A

B
C

*
A

B
C

STRUCTURE
FOR PURE METALS:
At the mould walls, metal cools rapidly. Produces
solidified skin or shell (thickness depends on
composition, mould temperature, mould size and
shape etc)
These of equiaxed structure.
Grains grow opposite to heat transfer through the mould
These are columnar grains
Driving force of the heat transfer is reduced away from
the mould walls and blocking at the axis prevents further
growth
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Development of a preferred texture

- for pure metal at a cool mould
wall.
A chill zone close to the wall and
then a columnar zone away from
the mould.

Solidified structures of metal solidified in a square mould

(a). Pure metal
(b). Solid solution
(c). When thermal gradient is absent
within solidifying metal

Three basic types of cast structures(a). Columnar dendritic;

(b). equiaxed dendritic;
(c). equiaxed nondendritic

Size and distribution of the overall grain structure throughout

a casting depends on rate & direction of heat flow
(Grain size influences strength, ductility, properties along
different directions etc.)
CONVECTION- TEMPERATURE GRADIENTS DUE TO
DIFFERNCES IN THE DENSITY OF MOLTEN METAL AT DIFFERENT
TEMPERATURES WITHIN THE FLUID - STRONGLY EFFECTS

THE GRAIN SIZE.

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DIRECTIONAL SOLIDIFICATION

Atm.Pressure

Pouring basin

MOULD
SPRUE

GATE

LIKE A PRESSURISED SYSTEM

MOULDERS
TOOLS
AND
EQUIPMENT

MOULDING BOARD
FLASK
SHOWEL
DRAW SPIKE
RIDDLE
SLICK
RAMMER
LIFTER
STRIKE-OFF BAR

Making a Core; (a). Ramming Core Sand. (b). Drawing the core box
(c). Baking in an oven (d) Pasting the core halves
(e). Washing the core with refractory slurry

1.
1

2.

3a

3.

2
4a

3b

4.

5.
4b
5

Make the pattern in

pieces, prepare the core.
Position the drag half of
pattern on mould board
in the drag half of flask
Prepare the drag half of
mould, roll drag over,
apply parting sand, place
the cope half of pattern
and flask, ram and strike
off excess sand
Separate flasks, remove
patterns, cut sprue, set
core in place, close flask
Now after clamping,
ready fro pouring.

THREE BOX MOULDING

PROCEDURE

LOAM MOULDING USING

LOAM SAND