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    Casting 2 by Mech Zone PDF

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    PrashantKumar
    Sand casting involves using a two-piece mold made of sand along with a core. Molten metal is poured into the mold cavity and allowed to solidify. Shell mold casting uses a two-piece pattern coated in a lubricant to make a shell mold from sand and resin, which is then filled with molten metal. Investment casting, also called lost wax casting, involves making a wax pattern, coating it with ceramic slurry to make a shell, and burning out the wax to leave a cavity that is filled with molten metal. Plaster mold and ceramic mold casting use slurries to form shells around a pattern that is later removed before filling the mold cavity.

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    Casting 2 by Mech Zone PDF

    Uploaded by

    PrashantKumar
    63 views13 pages
    Sand casting involves using a two-piece mold made of sand along with a core. Molten metal is poured into the mold cavity and allowed to solidify. Shell mold casting uses a two-piece pattern coated in a lubricant to make a shell mold from sand and resin, which is then filled with molten metal. Investment casting, also called lost wax casting, involves making a wax pattern, coating it with ceramic slurry to make a shell, and burning out the wax to leave a cavity that is filled with molten metal. Plaster mold and ceramic mold casting use slurries to form shells around a pattern that is later removed before filling the mold cavity.

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    Sand casting involves using a two-piece mold made of sand along with a core. Molten metal is poured into the mold cavity and allowed to solidify. Shell mold casting uses a two-piece pattern coated in a lubricant to make a shell mold from sand and resin, which is then filled with molten metal. Investment casting, also called lost wax casting, involves making a wax pattern, coating it with ceramic slurry to make a shell, and burning out the wax to leave a cavity that is filled with molten metal. Plaster mold and ceramic mold casting use slurries to form shells around a pattern that is later removed before filling the mold cavity.

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    © All Rights Reserved
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    Download as pdf or txt
    63 views13 pages

    Casting 2 by Mech Zone PDF

    Uploaded by

    PrashantKumar
    Sand casting involves using a two-piece mold made of sand along with a core. Molten metal is poured into the mold cavity and allowed to solidify. Shell mold casting uses a two-piece pattern coated in a lubricant to make a shell mold from sand and resin, which is then filled with molten metal. Investment casting, also called lost wax casting, involves making a wax pattern, coating it with ceramic slurry to make a shell, and burning out the wax to leave a cavity that is filled with molten metal. Plaster mold and ceramic mold casting use slurries to form shells around a pattern that is later removed before filling the mold cavity.

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    of 13

    Mech Zone

    Casting
    Process Part 2
    (SSC JE Mechanical/ GATE/ONGC/SAIL
    BHEL/HPCL/IOCL)
    Sand Casting

    cope: top half

    drag: bottom half

    core: for internal cavities

    funnel  sprue 
     runners  gate 
     cavity 
     {risers, vents}
    Shell Mould Casting

    - metal, 2-piece pattern, 175C-370C


    - coated with a lubricant (silicone)
    - mixture of sand, thermoset resin/epoxy
    - cure (baking)
    - remove patterns, join half-shells  mold
    - pour metal
    - solidify (cooling)
    - break shell  part
    Investment casting (lost wax casting)

    (a) Wax pattern (b) Multiple patterns


    (injection molding) assembled to wax sprue

    (c) Shell built 


    (d) dry ceramic immerse into ceramic slurry
    melt out the wax  immerse into fine sand
    fire ceramic (burn wax) (few layers)

    (e) Pour molten metal (gravity)


     cool, solidify (f) Break ceramic shell
    [Hollow casting: (vibration or water blasting)
    pouring excess metal before solidification

    (g) Cut off parts


    (high-speed friction saw)
     finishing (polish)
    Plaster-Mould, Ceramic-mould 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)
    Ceramic-mold: good finish
    high mp metals (steel, …) => impeller blades, turbines, …
    Vacuum Casting
    Similar to investment casting, except: fill mold by reverse gravity

    Easier to make hollow casting: early pour out


    Permanent Mould 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)


    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
    Die Casting
    - a type of permanent mold casting
    - common uses: components for
    rice cookers, stoves, fans, washing-, drying machines,
    fridges, motors, toys, hand-tools, car wheels, …

    HOT CHAMBER: (low mp e.g. Zn, Pb; non-alloying)


    (i) die is closed, gooseneck cylinder is filled with molten metal
    (ii) plunger pushes molten metal through gooseneck into cavity
    (iii) metal is held under pressure until it solidifies
    (iv) die opens, cores retracted; plunger returns
    (v) ejector pins push casting out of ejector die

    COLD CHAMBER: (high mp e.g. Cu, Al)


    (i) die closed, molten metal is ladled into cylinder
    (ii) plunger pushes molten metal into die cavity
    (iii) metal is held under high pressure until it solidifies
    (iv) die opens, plunger pushes solidified slug from the cylinder
    (v) cores retracted
    (iv) ejector pins push casting off ejector die
    Casting Defects

    A. Metallic Projections
    B. Cavities
    C. Discontinuities
    D. Defective surface
    E. Incomplete Casting
    F. Incorrect dimensions or shape
    G. Inclusions
    Casting Defects
    • Porosity : May be caused by shrinkage and/or gases. Thin sections
    solidify faster than thick sections; therefore the molten metal cannot
    be supplied to thick regions that are solidifying.

    • Gases become less soluble in a metal as it cools and solidifies,


    causing it to be expelled and sometimes form or expand porosity.

    • Chills: Pieces of material placed in the mold to speed up heat


    transfer in thicker areas of the part to prevent shrinkage porosity.

    • Internal chills are left within the cast part; external chills are
    removed.

    • Chills: Pieces of material placed in the mold to speed up heat


    transfer in thicker areas of the part to prevent shrinkage porosity
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    Mech Zone…
    (SSC JE Mechanical/ GATE/ONGC/SAIL
    BHEL/HPCL/IOCL)

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