Week 03 (Metal Casting-II) Part B

MANUFACTURING PROCESSES
Metal Casting
Department of Mechanical Engineering

HITEC University, Taxila Cantt
This Lecture
 Permanent Mold Casting
 Slush Casting
 Low Pressure/ Vacuum Casting
 Hot and Cold Chamber Die Casting
 Centrifugal Casting
 Types of Furnaces for Casting
 Casting Defects
 Design Considerations
2 Manufacturing Processes
Furnaces
 Several types of furnaces are most commonly used in
foundries
 Cupolas
 Crucible Furnaces
 Induction Furnaces
Cupolas
A vertical cylindrical furnace with a
tapping spout at the base. They are used
to melt Cast Irons.
 It consists of a large shell of steel plate
lined with refractory
 The charge consist of Iron , coke, flux
 Iron is usually a mixture of pig iron and
scrap
Cupolas
 Coke is the fuel used to heat the
furnace
 Flux is a basic compound like
Limestone that reacts with coke ash
and other impurities to form slag
 The slag protects metal from
reaction and reduce heat loss
Crucible Furnaces
 These furnaces melt the metal without
direct contact with a burner
 Also called indirect fuel fired furnaces
 Three types are commonly used in
industries
 Lift-out type
 Stationary
 Tilting
Lift out Crucible Furnace
Stationary Pot Crucible Furnace
Tilting Pot Crucible Furnace
Induction Furnace
Casting Defects
 There are numerous opportunities for
things to go wrong in a casting operation,
resulting in quality defect in the cast
product.
 Some defects are common to any and all
casting processes
 A brief description of these defects is
discusses next
Misruns
 A misrun is a casting that has solidified

before completely filling the mold
cavity. Typical cause include
 Fluidity of the molten metal is insufficient
 Pouring temperature is too low
 Pouring is done too slowly
 Cross-section of the mold cavity is too
thin
Cold Shut
 A cold shut occurs when two

portions of the metals flow
together but there is a lack of
fusion between them due to
premature freezing.
 Its causes are similar to those of
misrun
Shrinkage Cavity
 A depression or an internal void

in the casting caused by
solidification shrinkage that
restricts the amount of molten
metal available in the last region
to freeze.
Cold Shots
 When Splattering occurs during

pouring, solid globules of metal
are formed that become
entrapped in the casting.
 Pouring procedures and gating
system designs that avoid
splattering can prevent this
defect
Microporosity
 Small voids distributed

throughout the casting
caused by localized
solidification shrinkage of
the final molten metal .
 Usually associated with
alloys
Hot Tearing
 Also called hot cracking,

occurs when the casting is
restrained from contraction by
an unyielding mold during the
final stages of solidification or
early stages of cooling after
solidification
Casting defects for Sand Casting
 Some defects are related to the use of sand molds
 Sand blow
 Pinhole
 Sand wash
 Scab
 Penetration
 Mold shift
 Core shift
 Mold crack
Sand Casting Defects
Blow holes & Porosity
Shrinkage, Misruns & Hot tears
Metal Penetration, Cold Shuts & Sand Wash
Mold & Core Shifts
Comparing Different Casting Types
Design Rules for Casting
 Design the part so that the shape is cast
easily.
 Select a casting process and material suitable
for the part, size, mechanical properties, etc.
 Locate the parting line of the mold in the
part.
 Locate and design the gates to allow uniform
feeding of the mold cavity with molten metal.
 Select an appropriate runner
geometry for the system.
 Locate mold features such as sprue,
screens and risers, as appropriate.
 Make sure proper controls and good
practices are in place.
Riser Design
 The riser must not solidify before the
casting.
 The riser volume must be large enough
to provide a sufficient amount of liquid
metal to compensate for shrinkage in the
cavity.
 Junctions between casting and feeder
should not develop a hot spot where
shrinkage porosity can occur.
Riser Design
 Risers must be placed so that the liquid metal
can be delivered to locations where it is
most needed.
 There must be sufficient pressure to drive
the liquid metal into locations in the mold
where it is most needed.
 The pressure head from the riser should
suppress cavity formation and encourage
complete cavity filling.
 Sharp corners, angles and fillets should
be avoided because they act as stress raisers
and may cause cracking and tearing of the
metal during solidification.
 Section changes should be smooth. The
location of the largest circle that can be
inscribed in a particular region is critical.
 They will have the lowest cooling rate and are
termed as hot spots.
Eliminating Hotspots
Good and Poor Casting Designs

Week 03 (Metal Casting-II) Part B

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Week 03 (Metal Casting-II) Part B

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MANUFACTURING PROCESSES

Department of Mechanical Engineering

 A misrun is a casting that has solidified

 A cold shut occurs when two

 A depression or an internal void

 When Splattering occurs during

 Small voids distributed

 Also called hot cracking,

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