Presentation on:-

Metal Casting Process

Submitted By:-
Vaibhav Goyal
Roll No.:- 03216101416
Aman Mishra
Roll NO. :- 40616101416
 Objective

 Definition of casting
 Basic features
 Types of moulds
 Categories of casting process
 Further classification of Expendable and Permanent
mould casting
•  It is oldest
manufacturing
process.
Casting process
 Casting is a manufacturing process by which a
liquid material is usually poured into a mold,
which contains a hollow cavity of the desired
shape, and then allowed to solidify.

 The solidified part is also known as a casting,

which is ejected or broken out of the mold to
complete the process.
Casting process
 Casting materials are usually metals.
 Almost all metals can be cast.
 Casting is most often used for making complex
shapes that would be otherwise difficult to make
by other methods.
Basic Features
 Pattern: A pattern is made of wood or metal, is a replica of the final
product and is used for preparing mould cavity
 Riser: A column of metal placed in the mold to feed the casting as it
shrinks and solidifies. Also known as a "feed head."  
 Runner: The channel through which the molten metal is carried from
the sprue to the gate.
 Cores: A separated part of the mold, made of sand and generally
baked, which is used to create openings and various shaped cavities in
the casting.
 Gate: A channel through which the molten metal enters the casting
cavity.

Parting Line: Joint where mold separates to permit removal of
the pattern and which shows how and where to open the mold.
Sand: A sand which binds strongly without losing its
permeability to air or gases. 
Chaplet: A metal support used to hold a core in place in a mold.
Not used when a core print will serve.
Binders: Materials used to hold molding sand together.
Pouring basin: Filling the mold with molten metal.
Shrinkage: The decrease in volume when molten metal
solidifies.
Mould: The mould contains a cavity whose geometry determines
the shape of cast part.
Mould material should posses refractory characteristics and with
stand the pouring temperature
 Types of moulds

The various casting processes are classified according

to these different moulds

• open mould
• closed mould
 Types of moulds
• Open mould
in which the liquid metal is simply
poured until it fills the open cavity. (fig. a)

• Closed mould
the closed mold is provided to permit the
molten metal to flow from outside the mold cavity.
(fig. b)
• the closed mold is more important categories in
production casting operation.
Open and Closed Mould
Categories of casting process
 Casting process divide onto two broad categories
according to types of mold used;

o Expandable mould casting

o Permanent mould casting
 Expandable mould casting
Expandable mould means that :
the mold in which the molten metal is
solidifies must be break or destroyed to remove the
casting.
Or
After solidification of molten metal the mold is break
to remove the desired casting. (sand casting)

Expandable mould materials:

the mold are made out of sand, plaster,
and similar materials.
Classification of casting processes
Expandable mold casting
Expandable mold casting:
1.permanent pattern:
SAND CASTING
 Common features

Schematic illustration of sand casting showing various features.

Sand Casting
Advantages Disadvantages  Recommended
Application

Least Expensive in Dimensional Use when

small quantities (less accuracy inferior to strength/weight
than 100) other processes, ratio permits
requires larger
Ferrous and non - tolerances Tolerances,
ferrous metals may surface finish and
be cast Castings usually low machining
exceed calculated cost does not
Possible to cast very weight warrant a more
large parts. expensive process
Surface finish of
• Least ferrous castings
expensive tooling usually exceeds 125
RMS
Expandable mold casting:
Expendable pattern:
INVESTMENT CASTING:

 Use gravity to fill the mold.

 Mold is destroyed to remove casting
 Metal flow is slow
 Walls are much thicker than in die casting.
 Cycle time is longer than die casting because of inability of mold
material to remove heat.
 The investment casting process uses expendable patterns made
of investment casting wax.
Investment Casting
Advantages Disadvantages  Recommended
Application
Close dimensional Costs are higher Use when
tolerance than Sand, Complexity
Permanent Mold or precludes use of
Complex shape, fine Plaster process Sand or
detail, intricate core Castings Permanent Mold
sections and thin Castings
walls are possible
The process cost is
Ferrous and non- justified through
ferrous metals may savings in
be cast machining or
brazing
As-Cast" finish (64 -
125 RMS) Weight savings
justifies increased
cost
Permanent mold casting
o In permanent mold casting, the mold is
reused many times.
o The molds are commonly made of steel or
cast iron.
o The Metals commonly cast in the
permanent mold casting include aluminum,
magnesium and copper- based alloys( brass ,
bronze)
Permanent mold casting
Types permanent mold casting

Two basic two types of permanent

mold casting as under
o Die casting
o Centrifugal casting
Die casting:
o Die casting is permanent-mold casting process
in which the molten metal is injected into
mold cavity under high pressure. The pressure
is maintained during solidification, after
which the mold is opened and part is removed.
o Typical pressures are 7 to 350 MPa.
o The molds used in this casting operation is
called dies; hence the name die casting
Die casting:
Die casting machines:
 Two types of die casting machines that
as under
o Hot chamber die casting
o Cold chamber die casting
Hot chamber die casting:
o In hot chamber die- casting machines, the molten metal
is poured into a heated chamber from an external melting
container, and piston is used to inject the molten metal
under a high pressure into die cavity.
o Typically injection pressures are 7 to 35 mpa.
o This process only used for the low-melting-point metals.
(zinc,tin ,lead and, sometimes magnesium)
Cold chamber die-casting :
o In which the molten metal poured into an
unheated chamber, and piston is used to inject
the liquid metal under a high pressures into the
die cavity
o Injection pressures used in these machine are
typically 14 to 140 mpa.
Centrifugal casting:
o In centrifugal casting the mold is rotated at high
speed so that the centrifugal force is produced
that distributes the molten metal to the outer
regions of the cavity.
o Examples of parts made by this process include
pipes, tubes bushing and rings.
Advantages of permanent mold
casting
o High production rates possible.
o Close tolerance is possible for small
parts.
o Good surface finish.
o Thin sections are possible.
o Rapid solidification.
Limitation of permanent mold
casting
o Only used for low melting point metals.
o More intricate shapes are not achieved
o Mold is expensive.

 Note:(More intricate shapes are not achieved by

the permanent mold casting)
Selecting the Right Metal Casting
Process
 For any Metal Casting Process, selection of right alloy, size, shape,
thickness, tolerance, texture, and weight, is very vital.
 Views of the Tooling Designer; Foundry / Machine House needs,
customer's exact product requirements, and secondary operations like
painting, must be taken care of before selecting the appropriate Metal
Casting Process.
 Tool cost.
 Economics of machining versus process costs.
 Adequate protection / packaging, shipping constraints, regulations of
the final components, weights and shelf life of protective coatings also
play their part in the Metal Casting process.

 Thank
You
Pankaj Sir!