Metal Casting Processes

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PEMP EMM2512

Metal Casting Processes


Dr. N S Mahesh Professor and Head Department of Mechanical and Manufacturing Engg

M.S Ramaiah School of Advanced Studies - Bangalore

PEMP EMM2512

Session Objectives
At the end of the session students should have understood
Fundamentals of metal casting Metal casting processes
Sand casting Die casting Investment casting Continuous casting

Case studies
Cylinder block Piston
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PEMP EMM2512

Manufacturing Processes
Manufacturing Processes

Casting:
Expendable mold Permanent mold

Forming & Shaping:


Rolling Forging Extrusion Drawing Sheet forming PM

Machining:
Turning Milling Drilling Boring Grinding Shaping broaching

Joining:
Welding Brazing Soldering Bonding assembly

Finishing:
Lapping Polishing Deburring Surface treating coating

M.S Ramaiah School of Advanced Studies - Bangalore

PEMP EMM2512

What is casting?
Processing methods affect material properties differentially (and therefore the final component) Casting
Mostly Metals

Casting involves pouring/injecting molten material into a prepared cavity. On solidification the metal takes the form of the cavity. Cavity is formed within a Mould. Choice of manufacturing technique dependant upon required properties of component Suitability cost

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PEMP EMM2512

Applicability of Casting
Excellent for large and complex shapes, particularly with internal features Can produce net shape or near net shape components Used where mechanical properties are not of paramount importance Used where solid state processing is difficult or uneconomical

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PEMP EMM2512

ALUMINUM ALLOY CASTINGS

Large, complex sand casting by rigid mould technology meeting stringent radiographic and penetrant NDT stds.

Aeroengine gear case casting in Al-SiMg alloy A 356

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PEMP EMM2512

MAGNESIUM ALLOY CASTINGS

Main Gear Box Housing of the Advanced Light Helicopter

Large surface area with wall thickness of 5 mm. As- cast internal oil passages, 5-12 mm dia, running to a total length of 500 mm. Casting weight : 50 kgs, Process : Rigid mould

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PEMP EMM2512

MAGNESIUM ALLOY CASTINGS

Large diameter, large surface area, thin walled casting for missile applications

Reduction gear cover casting for a helicopter engine with as -cast internal oil passages

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PEMP EMM2512

Casting processes

M.S Ramaiah School of Advanced Studies - Bangalore

PEMP EMM2512

Metal Casting Processes

Expendable mold

Permanent mold

Single-crystal growing

Sand Shell Expandable pattern Plaster Ceramic Investment

Slush Pressure Die Centrifugal Squeeze Semisolid

Single-crystal for Microelectronics Single-crystal Turbine blades Directional solidification


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PEMP EMM2512

Solidification of metals
Encourage smaller dendrites via mixing using convection currents or physical mixing (vibration) Innoculants -nucleating agents, form equiaxed dendrites with uniform distribution Quick cooling desirable Heat metal just enough Methods to ensure rapid cooling

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PEMP CASTING PROCESSES OPERATIONS - FLOW CHART COMPONENT DRAWING ESTIMATES & QUOTATION RECEIPT OF ORDER EMM2512

CASTING DRG DRAFT; M/C ALLOWANCE; CORNER & FILLET RADII; PARTING LINE.

TOOL DRG. PATTERN & CORE BOX /DIE DESIGN; CONTRACTION ALLOWANCE; AUXILLIARY TOOLS LIKE CHILLS, TEMPLATES, MOULD BOXES Etc.

METHODS DRG. POURING & FEEDING SYSTEM MFG. PROCESS DETAILS MOULD MEDIA METAL TEMP. Etc.

TEST SHEET DETAILED TEST REQTS. AND ACCEPTANCE STANDARDS

TOOL MFG. INCLUDING AUXILLIARY TOOLS SAND MIXING AND TESTING MOULD AND CORE PREPERATION OR DIE PREPERATION ASSEMBLY CASTING KNOCK OUT FETTLING AND CLEANING HEAT TREATMENT NDT AND INSPECTION SHIPPING FURNACES MELT AND REFINE REJECTION

RECLAIMED SAND

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PEMP EMM2512

Sand Casting with a core in place

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PEMP EMM2512

A Review of Casting Processes


Shell mold casting Investment casting Permanent mold casting Pressure die casting Centrifugal casting

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PEMP EMM2512

Shell Mold Casting

- Metallic 2-piece pattern, 175C-370C - coated with a lubricant (silicone) - mixture of sand, thermoset resin/epoxyurea formaldehyde - cure (baking) -remove patterns, join half-shells mold - pour metal - solidify (cooling) - break shell part

Applications: small mechanical parts requiring high precision such as gear housings, cylinder heads and connecting rods etc
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Expendable Pattern Casting


- Styrofoam pattern (PS) dipped in refractory slurry dried - sand (support) - pour liquid metal -foam evaporates, metal fills the shell - cool, solidify - break shell part Applications: cylinder heads, crankshafts, brake components and manifolds, machine bases Al engine blocks and other components of the GM saturn automobiles are made by this process
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Plaster-mold, Ceramic-mold casting


Plaster-mold slurry: plaster of paris (CaSO4), talc, silica flour Ceramic-mold slurry: silica, powdered Zircon (ZrSiO4) - The slurry forms a shell over the pattern - Dried in a low temperature oven - Remove pattern - Backed by clay (strength), baked (burn-off volatiles) - cast the metal - break mold part Plaster-mold: good finish (Why ?) plaster: low conductivity => low warpage, residual stress low mp metal (Zn, Al, Cu, Mg), gears, valves, fittings, tooling and ornaments

Ceramic-mold:

good finish high mp metals (steel, ) => impeller blades, turbines, cutters for machining operations, dies for metal working and molds for making plastics or rubber components
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Investment casting (lost wax process)


(a) Wax pattern (injection molding) (b) Multiple patterns assembled to wax sprue

(d) dry ceramic melt out the wax fire ceramic (burn wax)

(c) Shell built immerse into ceramic slurry immerse into fine sand (few layers)

(e) Pour molten metal (gravity) cool, solidify [Hollow casting: pouring excess metal before solidification

(f) Break ceramic shell (vibration or water blasting)

(g) Cut off parts (high-speed friction saw) finishing (polish) M.S Ramaiah School of Advanced Studies - Bangalore

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Precision / Investment Castings

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PEMP EMM2512

Precision / Investment Castings

Precision torque converter castings for aeroengine

Thin walled investment castingrope pulley- for a commuter aircraft

Investment casting for instrument frame M.S Ramaiah School of Advanced Studies - Bangalore

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PEMP EMM2512

Permanent mold casting MOLD: made of metal (cast iron, steel, refractory alloys) CORE: (hollow parts) - metal: core can be extracted from the part - sand-bonded: core must be destroyed to remove Mold-surface: coated with refractory material - Spray with lubricant (graphite, silica) - improve flow, increase life - good tolerance, good surface finish - low mp metals (Cu, Bronze, Al, Mg)
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PEMP EMM2512

GDC or Permanent Mould Casting



Non expendable metal moulds 2% Ni. Cast iron, steel Pour by gravity at die temp 150 to 2000c Life 1000 to 2000 pieces Better strength Better dimensions Better Grains Low Incidence of Gas Porosity Faster rate of production Restriction of Alloys / Shape / Geometry Require good venting Incorporate cooling ribs in die (thick sections)
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PEMP EMM2512

Metal Mould Casting Gravity Die

Two part permanent mould mounted on moulding machine, with centre core designed to pull down for casting removal
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Application : Brake System Weight : approx. 2.5 Kgf

Application : Brake System Weight : approx. 0.750 Kgf (set)

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Application : Transmission3 (gear box) Weight : approx. 3.25 Kgf

Application : Transmission3 (gear box) Weight : approx. 1.5 Kgf

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PEMP

PDC (Pressure Die Casting)


pressure

EMM2512

Liquid metal injected into steel die at high velocity solidifies under Injection Pressure : 7 MPa to 140 MPa Locking force - 2000 ton Casting rate: 5 10 pieces / minute Die material: 0.3 C; 5.0 Si; 1.3 Mo; 1.0V. hardened to 420 460 BHN Die life: 50,000 to 2 lakh pieces Excellent surface finish / reproducibility Excellent dimensional accuracy: 0.05mm Castability 1mm (Al alloy) Alloy restriction / shape & size restriction Prone to gas porosity (finely dispersed N)-can be avoided by O2 purging
producing Al2O3 surface
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PEMP EMM2512

Hot Chamber Die Casting

Used for lower melting point alloys (zinc and magnesium) Mold pressures usually 7 MPa to 14 MPa but can be up to 35 MPa.
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PEMP EMM2512

Cold Chamber Die Casting

Used for higher melting point alloys aluminum and copper based Die pressures from 35 to 140 MPa
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Pressure die cast components for automotive applications

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Centrifugal casting
- permanent mold - rotated about its axis at 300 ~ 3000 rpm - molten metal is poured

- Surface finish: better along outer diameter than inner, - Impurities, inclusions, closer to the inner diameter
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PEMP EMM2512

Centrifugal casting
Eg. Cylinder Liners, Piston rings etc.

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PEMP EMM2512

Summary of Process Capabilities


Process Alloy Range Weight Range Kg Economic Quantity Thin Section mm >5 >2 > 1.5 >5 >4 > 0.5 Surface Finish m 6.3 to 25 3.2 to12.5 0.8 to 3.2 3.2 to 6.3 1.6 to 6.3 0.4 to 3.2 0.5 0.5 0.25 0.55 0.15 Dimensional Accuracy mm per 100mm

Sand Evaporative Investment Gravity Die LPDC HPDC

Most Most Most Nonferrous Nonferrous Nonferrous

0.1 to 100,000 0.5 to 5000 0.05 to 250 0.1 to 70 5 to 25 0.05 to 25

1 to 100,000 1000 + 1000 + 1000 + 1000 + 5000 +

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Different Casting Processes


Process
Sand Shell mold Expendable pattern Plaster mold Ceramic mold Investment Permanent mold Die

PEMP EMM2512

Advantages
many metals, sizes, shapes, cheap better accuracy, finish, higher production rate Wide range of metals, sizes, shapes complex shapes, good surface finish complex shapes, high accuracy, good finish complex shapes, excellent finish good finish, low porosity, high production rate Excellent dimensional accuracy, high production rate Large cylindrical parts, good quality

Disadvantages
poor finish & tolerance limited part size patterns have low strength non-ferrous metals, low production rate small sizes small parts, expensive Costly mold, simpler shapes only costly dies, small parts, non-ferrous metals Expensive, few shapes

Examples
engine blocks, cylinder heads connecting rods, gear housings cylinder heads, brake components prototypes of mechanical parts impellers, injection mold tooling jewellery gears, gear housings gears, camera bodies, car wheels pipes, boilers, flywheels

Centrifugal

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Casting Defects
Discontinuities in castings
that exhibit a size, shape, orientation, or location that makes them detrimental to the useful service life of the casting

PEMP EMM2512

Some casting defects are


remedied by minor repair or refurbishing techniques, such as welding

Other casting defects are


cause for rejection of the casting
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PEMP EMM2512

Manufacturing processes of a cast piston made by permanent mold casting


T7 heat treatment includes four processes Solution treatment

Water quenching

Ageing

Air cooling

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PEMP EMM2512

Summary
Fundamentals of metal casting and different methods of casting have been studied Casting defects, design considerations were discussed Case studies such as casting of Cylinder block and Piston have been discussed

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