Casting & Welding MF F343: BITS Pilani

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Casting & Welding

MF F343
Dr. Sujith R

BITS Pilani Assistant Professor, BITS Pilani, Hyderabad Campus


Hyderabad Campus
sujith@hyderabad.bits-pilani.ac.in
Casting

• Primary manufacturing process

• Melting & solidification

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Advantages of casting

• Size does not matter

• Complex shapes

• Possible to cast a wide variety of materials: Cast Iron

• Losses is minimal

• Production cost is low

• Isotropic properties
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Limitations

• Not all materials can be casted

• Limited dimensional accuracy and surface finish

• More labor intensive

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Foundry industry: Global
scenario

• In 2015, world casting production reached 104.1 million


metric tons

• China is the top producing nation with 44% of total casting


production

• USA & India combined 20% of production

Data retrieved from Foundry informatics center (2017)

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Production of Castings in
India

Data retrieved from Foundry informatics center (2017)


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Sector-wise consumer in
India

Data retrieved from Foundry informatics center (2017)


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Copper frog 3200 BC,
Mesopotamia

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11 cm bronze dancing girl,
3000 BC, Mohenjedaro

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Historical developments

• 500 AD: Cast crucible steel is first produced in India. But,


technology lost until 1750 (Ukku/Wootz)

• 1455: Dillenburg Castle in Germany is the first to use CI pipe to


transport water

• 1480: Birth of Vannoccio Biringuccio (1480-1539), the "father


of the foundry industry," in Italy. He is the first man to
document the foundry process in writing

• 1750: Benjamin Huntsman reinvents the process of cast


crucible steel in England. Since the metal is completely molten,
it also allows for alloy steel production

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Historical developments
1809: Centrifugal casting is developed by A. G. Eckhardt of Soho,
England.
1896: American Foundrymen's Association (renamed American
Foundrymen's Society in 1948 and now called the American Foundry
Society) is formed.
1897: Investment casting is rediscovered by B.F. Philbrook of Iowa. He
uses it to cast dental inlays.
1947: The Shell process, invented by J. Croning of Germany during
WWII, is discovered by U.S. officials and made public.
1958: H.F. Shroyer is granted a patent for the full mold process, the
forerunner of the expendable pattern (lost foam) casting process.
1971: Rheocasting is developed at Massachusetts Institute of
Technology (MIT).
1996: Cast metal matrix composites are first used in a production model
automobile in the brake rotors for the Lotus Elise.

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Basic steps in casting

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Casting terms
Flask: A metal or wood frame in which the mold is formed. It is
referred to by various names such as drag, cope and cheek

Pattern: It is the replica of the final object to be made. The mold


cavity is made with the help of pattern.

Parting line: This is the dividing line between the two molding
flasks that makes up the mold.

Molding sand: Sand, which binds strongly without losing its


permeability to air or gases. It is a mixture of silica sand, clay,
and moisture in appropriate proportions.
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Casting terms
Facing sand: The small amount of carbonaceous material
sprinkled on the inner surface of the mold cavity to give a
better surface finish to the castings.
Core: A separate part of the mold, made of sand and generally
baked, which is used to create openings and various
shaped cavities in the castings.
Pouring basin: A small funnel shaped cavity at the top of the
mold into which the molten metal is poured.
Sprue: The passage through which the molten metal, from the
pouring basin, reaches the mold cavity. In many cases it
controls the flow of metal into the mold.
Runner: The channel through which the molten metal is carried
from the sprue to the gate.
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Casting terms
Gate: A channel through which the molten metal enters the
mold cavity.

Chaplets: Chaplets are used to support the cores inside the


mold cavity to take care of its own weight and overcome the
metallostatic force.

Riser: A column of molten metal placed in the mold to feed the


castings as it shrinks and solidifies. Also known as “feed
head”.

Vent: Small opening in the mold to facilitate escape of air and


gases.
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Pattern making

BITS Pilani, Hyderabad Campus


Pattern

• Replica of the object to be made with some modifications


(metallurgical and mechanical reasons).

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Functions of a pattern

• Produces a mold cavity

• Core prints might be required if the casting requires a recess

• Runner, gates, and risers used for feeding molten metal in


the mold cavity may form a part of the pattern

• Patterns properly made and having finished and smooth


surfaces reduce casting defects

• A properly constructed pattern minimizes the overall cost of


the castings
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Pattern materials

• Wood, metals and alloys, plastic, plaster of Paris, rubbers,


wax, and resins

Pre-requisites:
Easily worked, shaped and joined
Light in weight
Strong, hard and durable
Resistant to wear and abrasion
Resistant to corrosion, and to chemical reactions
Dimensionally stable and unaffected by variations in
temperature and humidity
Available at low cost
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Pattern material
characteristics
Characteristic Wood Aluminium Steel Plastic Cast Iron

Machinability E G F G G

Wear P G E F E
resistance
Strength F G E G G

Weight E G P G P

Repairability E P G F G

Corrosion E E P E P
resistance

E – excellent G – good F – fair P - poor

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Pattern allowances

1. Shrinkage or contraction allowance

2. Draft or taper allowance

3. Machining or finish allowance

4. Distortion or camber allowance

5. Rapping allowance

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Shrinkage allowance

Amount the pattern should be made larger than the


casting to provide for the total contraction
Material Dimension Shrinkage allowance
(inch/ft)

Grey Cast Iron Up to 2 feet 0.125


2 feet to 4 feet 0.105
over 4 feet 0.083
Cast Steel Up to 2 feet 0.251
2 feet to 6 feet 0.191
over 6 feet 0.155
Aluminum Up to 4 feet 0.155
4 feet to 6 feet 0.143
over 6 feet 0.125
Magnesium Up to 4 feet 0.173
Over 4 feet 0.155

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Machining or finish
allowance

Metal Dimension (inch) Allowance (inch)

Up to 12 0.12
Cast iron 12 to 20 0.20
20 to 40 0.25

Up to 6 0.12
Cast steel 6 to 20 0.25
20 to 40 0.30

Up to 8 0.09
Non ferrous 8 to 12 0.12
12 to 40 0.16

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Draft or taper allowance

Height of the
Draft angle for Draft angle for
Pattern material given surface
external surfaces internal surfaces
(inch)
1 3.00 3.00
1 to 2 1.50 2.50
Wood 2 to 4 1.00 1.50
4 to 8 0.75 1.00
8 to 32 0.50 1.00
1 1.50 3.00
1 to 2 1.00 2.00
Metal and plastic 2 to 4 0.75 1.00
4 to 8 0.50 1.00
8 to 32 0.50 0.75

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Distortion/Camber
Allowance

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Rapping allowance

• For the easy pattern removal rapping is carried out.

• Leads to enlargement of mold cavity.

• Original pattern dimension is to be reduced to take this


into account.

• Negative allowance.

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