CH 3

CHARTER 3
METAL CASTING
PGS.TS. NGUYỄN NGỌC HÀ 1

1. OVERVIEW OF
METAL CASTING

1.1. GENERAL
1.1.1. History
 First castings were made during
4000 – 3000 BC
 Ancient Greece; bronze statue
casting circa 450 BC
 Iron works in early Europe, e.g.
cast iron cannons from England
circa 1543
1.1.2. Metal casting ?
 Process in which molten metal flows by gravity or
other force into a mold where it solidifies in the
shape of the mold cavity (Hốc/lòng khuôn)
 Steps in casting seem simple:
1. Prepare mold for pour
2. Pour molten metal into mold
3. Allow metal to solidify
4. Break up the mold to remove casting
5. Clean and inspect casting
Castings (Vật đúc)

1.1.3. Capabilities and advantages of casting
Can create complex part geometries
Can create both external and internal shapes
Some casting processes are net shape; others
are near net shape
Can produce very large or very small parts
Some casting methods are suited to mass
production (Sản xuất hàng loạt)
1.1.4. Disadvantages of casting
Limitations on mechanical properties
Poor dimensional accuracy and surface finish
(độ nhẵn bề mặt) for some processes; e.g., sand
casting
Safety hazards to workers due to hot molten
metals
Environmental problems
1.2. THE MOLD IN CASTING
Contains cavity whose geometry determines
part shape
Molds are made of a variety of materials,
including sand, plaster, ceramic, metal …

1.3. CASTING TERMINOLOGY

• Mould, mold: khuôn đúc • Core: lõi, ruột
• Cope: (nửa) khuôn trên • Gate, gate system: hệ
• Drag: (nửa) khuôn dưới thống rót
• Parting line: mặt phân • Pouring basin (cup): cốc
khuôn rót, phễu rót
• Flask: hòm khuôn • Sprue: ống rót
• Sand, mold sand, mold • Runner: Rãnh dẫn
mixture: hỗn hợp làm • Riser: đậu ngót
khuôn • Open riser: đậu ngót hở
• Mold cavity: hốc khuôn, • Blind riser: đậu ngót kín
lòng khuôn • Vent: đậu hơi
• Flask: The box containing the mold
• Cope: The top half of any part of a 2-part mold
• Drag: The bottom half of any part of a 2-part mold
• Core: A shape inserted into the mold to form
internal cavities
• Core Print: A region used to support the core
• Mold Cavity: The hollow mold area in which metal
solidifies into the part
• Riser: An extra cavity to store additional metal to
prevent shrinkage
• Gating System: Channels used to deliver metal into
the mold cavity
• Pouring Cup: The part of the gating system that
receives poured metal
• Sprue: Vertical channel
• Runners: Horizontal channels
• Parting Line: Interface that separates the cope and
drag of a 2-part mold
• Draft: Taper on a pattern or casting that allows
removal from the mold
• Core Box: Mold or die used to produce cores
• Casting: The process and product of solidifying metal
in a mold
2. SAND MOLD MATERIALS

2.1. INTRODUCTION
 Mold Materials: Refractories (Vật liệu chịu lửa), Binders
(Chất dính), Additives (Phụ gia)
 Mold Mixtures: Refractories + Binders + Additives
 Binders: Sand is held together by binders
 Additives: are sometimes combined with the
mixture to enhance strength and/or permeability
(Độ thông khí)

2.2. MOLD SAND
80-98% mass of mold mixture
Grain size: 0,016-2mm
The most important properties:
 Chemical composition
 Size and shape of grains
 Melting temperature
 Thermal expansion

Types of Mold Sand
Silica (SiO2) (Most common)
Zircon (ZrSiO4)
Olivine (Mg2SiO4)
Iron silicate (Fe2SiO4)
Chromate (FeCr2O4)

2.3. BINDERS USED WITH
FOUNDRY SAND
Sand-clay mixture: Sand is held together by a
mixture of water and bonding clay
Other bonding agents also used in sand
molds:
– Organic resins (e g , phenolic resins)
– Inorganic binders (e g , clay, sodium silicate and
phosphate)
3. SAND MOLD CASTING

3.1. OVERVIEW OF SAND CASTING
3.1.1. Steps in Sand Casting

3.1.2. Advantages
Most widely used casting process
Nearly all alloys can be sand casted, including
metals with high melting temperatures
It is possible to manufacture parts with
complex shapes
Parts ranging in size from small to very large
Production quantities from one to millions
3.1.3. Disadvantages
Porosity
Poor dimensional control for some processes
Poor surface finish for some processes
Limitation on mechanical properties
Safety hazard
Environmental hazard
Sand-Cast Parts
A large sand casting weighing 680 kg for an air

compressor frame
3.2. TYPES OF SAND MOLDS
a) Green Sand Molds (Khuôn tươi): The most common
type consisting of forming the mold from damp
molding sand (silica, clay and moisture)
b)Skin-dried Molds (Khuôn sấy bề mặt)
c) Dry Sand Molds (Khuôn khô): baked before being used.
A dry sand mold holds its shape when poured and is
free from gas troubles due to moisture.
3.3. SAND CASTING PATTERN
(Mẫu đúc)
Patterns may be made from a variety of

materials:
• Wood
• Metal
• Hard Polymers
• EPS (Styrofoam)
3.3.1. One-Piece Pattern
(Mẫu nguyên)

3.3.2. Split Pattern
(Mẫu bổ đôi)
 Split pattern, showing

the two sections
together and separated

3.3.3. Match-Plate
(Tấm mẫu)

3.3.4. Cope-and-Drag Split Patterns
(Tấm mẫu 2 mặt)
Cope-and-drag pattern for producing two heavy parts.

(Left) Cope section; (right) drag section. (Note: These are
two separate pattern boards)
3.4. MOLDING PROCEDURE
One-Piece Pattern

Split Pattern

Match-Plate

3.5. CORES (Ruột) AND CORE MAKING
3.5.1. Introduction
Casting processes are unique in their ability to
incorporate internal cavities -or reentrant
sections with relative ease
To produce these features, however, it is often

necessary to use cores as part of the mold

V-8 engine block (bottom center) and the five dry-sand cores that are
used in the construction of its mold. (Courtesy of General Motors
Corporation, Detroit, MI.)
3.5.2. Types of Cores

3.6. MELTING AND POURING
3.6.1. Introduction
 The quality of casting depends on the method of
melting. The melting technique should provide
molten metal at required temperature, but should
also provide the material of good quality and in the
required quantity
 The two main consideration during pouring are the
temperature and pouring rate
3.6.2. Furnaces for Casting Processes
Furnaces most commonly used in foundries:

– Cupolas
– Crucible furnaces
– Electric-arc furnaces
– Induction furnaces

Electric Arc Furnace Cupola
(Lò hồ quang) (Lò đứng)
Induction furnace Crucible furnace
(Lò cảm ứng) (Lò nồi)

3.6.3. Ladles (Thùng rót)
Moving molten metal from melting furnace to
mold is sometimes done using crucibles (nồi lò)
More often, transfer is accomplished by ladles
Two common types of ladles: (a) crane ladle,

and (b) two-man ladle
4. SPECIAL CASTING PROCESSES

4.1. PERMANENT MOLD CASTING
PROCESSES
 Economic disadvantage of expendable mold
casting: a new mold is required for every casting
 In permanent mold (Khuôn vĩnh cửu) casting, the mold
is reused many times
 The major processes include:
• Basic permanent mold casting/Gravity die casting (Đúc
trong khuôn kim loại)
• Die casting/Pressure die casing (Đúc áp lực)
• Centrifugal casting (Đúc li tâm)

4.1.1. The Basic Permanent Mold Process
 Uses a metal mold constructed of two sections

designed for easy, precise opening and closing
 Molds used for casting lower melting point
alloys are commonly made of steel or cast iron

 Molds used for casting steel, cast iron must be

made of heat-resistant steels, due to the very
high pouring temperatures
 Due to high mold cost, process is best suited
to high volume production and can be
automated accordingly


Advantages and Limitations of
Permanent Mold Casting
 Advantages:
• Good dimensional control and surface finish
• More rapid solidification caused by the cold metal
mold results in a finer grain structure, so stronger
castings are produced
 Limitations:
• Simple part geometries compared to sand casting
because of the need to open the mold
• High cost of mold

4.1.2. (Pressure) Die Casting
 A permanent mold casting process in which
molten metal is injected into mold cavity
under high pressure
 Pressure is maintained during solidification,
then mold is opened and part is removed
 Molds in this casting operation are called dies;
hence the name die casting
4.1.2. Die Casting
 Use of high pressure to force metal into
die cavity is what distinguishes this from
other permanent mold processes
 Two main types:
1. Hot-chamber (Buồng nóng) machine

2. Cold-chamber (Buồng nguội) machine
Hot-Chamber Die Casting

Hot-Chamber Die Casting
 Metal is melted in a container, and a piston
injects liquid metal under high pressure into
the die
 High production rates
 Applications limited to low melting-point
metals that do not chemically attack plunger
and other mechanical components
 Casting metals: zinc, tin, lead, magnesium …
Cold-Chamber Die Casting

Cold-Chamber Die Casting
 Molten metal is poured into unheated chamber
from external melting container, and a piston
injects metal under high pressure into die cavity
 High production but not usually as fast as
hot-chamber machines because of pouring step
 Casting metals: aluminum, brass, and
magnesium alloys
Advantages of Die Casting
Economical for large production quantities

Good dimensional accuracy and surface finish
Thin sections are possible
Rapid cooling provides small grain size and
good strength to casting

Limitations of Die Casting
 Generally limited to metals with low metal

points
 Part geometry must allow removal from die
cavity
 Porosity - due to air & gasses entrained in the
filling process

4.2. EXPENDABLE MOLD PROCESSES
 Sand Casting
 Shell Molding (Khuôn vỏ mỏng)
 Vacuum Molding
 Evaporative Pattern (Mẫu hóa khí) Casting (EPC)
 Investment Casting (Đúc trong khuôn mẫu chảy)
 Plaster Mold and Ceramic Mold Casting
…
4.2.1. Shell Molding
Casting process in which the mold is a thin
shell of sand held together by resin binder
62
Advantages of Shell Molding
Smoother cavity surface permits easier flow of

molten metal and better surface finish on casting
Good dimensional accuracy
Machining often not required
Mold collapsibility usually avoids cracks in casting
Can be mechanized for mass production

Disadvantages of Shell Molding
 More expensive metal pattern
 Difficult to justify for small quantities

4.2.2. Investment Casting (Lost Wax)
 A pattern made of wax is coated with a
refractory material to make mold, after which
wax is melted away prior to pouring molten
metal
 "Investment" comes from one of the less
familiar definitions of "invest" - "to cover
completely," which refers to coating of
refractory material around wax pattern
 It is a precision casting process - capable of
castings of high accuracy and intricate detail

4.2.2. Investment Casting

Advantages of Investment Casting
 Parts of great complexity and intricacy can be
cast
 Close dimensional control and good surface
finish
 Wax can usually be recovered for reuse
 Additional machining is not normally
required - this is a net shape process
Disadvantages of Investment Casting
 Many processing steps are required
 Relatively expensive process

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CHARTER 3

PGS.TS. NGUYỄN NGỌC HÀ 1

PGS.TS. NGUYỄN NGỌC HÀ 2

PGS.TS. NGUYỄN NGỌC HÀ 5

PGS.TS. NGUYỄN NGỌC HÀ 9

PGS.TS. NGUYỄN NGỌC HÀ 10

PGS.TS. NGUYỄN NGỌC HÀ 14

PGS.TS. NGUYỄN NGỌC HÀ 15

PGS.TS. NGUYỄN NGỌC HÀ 16

Silica (SiO2) (Most common)

Iron silicate (Fe2SiO4)

PGS.TS. NGUYỄN NGỌC HÀ 17

PGS.TS. NGUYỄN NGỌC HÀ 19

PGS.TS. NGUYỄN NGỌC HÀ 20

Poor dimensional control for some processes

Poor surface finish for some processes

Limitation on mechanical properties

A large sand casting weighing 680 kg for an air

Patterns may be made from a variety of

PGS.TS. NGUYỄN NGỌC HÀ 26

 Split pattern, showing

PGS.TS. NGUYỄN NGỌC HÀ 27

PGS.TS. NGUYỄN NGỌC HÀ 28

Cope-and-drag pattern for producing two heavy parts.

PGS.TS. NGUYỄN NGỌC HÀ 30

PGS.TS. NGUYỄN NGỌC HÀ 31

PGS.TS. NGUYỄN NGỌC HÀ 32

To produce these features, however, it is often

PGS.TS. NGUYỄN NGỌC HÀ 33

PGS.TS. NGUYỄN NGỌC HÀ 35

Furnaces most commonly used in foundries:

PGS.TS. NGUYỄN NGỌC HÀ 38

PGS.TS. NGUYỄN NGỌC HÀ 40

Two common types of ladles: (a) crane ladle,

PGS.TS. NGUYỄN NGỌC HÀ 43

PGS.TS. NGUYỄN NGỌC HÀ 44

 Uses a metal mold constructed of two sections

PGS.TS. NGUYỄN NGỌC HÀ 45

 Molds used for casting steel, cast iron must be

PGS.TS. NGUYỄN NGỌC HÀ 46

PGS.TS. NGUYỄN NGỌC HÀ 47

PGS.TS. NGUYỄN NGỌC HÀ 49

1. Hot-chamber (Buồng nóng) machine

PGS.TS. NGUYỄN NGỌC HÀ 54

PGS.TS. NGUYỄN NGỌC HÀ 56

Economical for large production quantities

PGS.TS. NGUYỄN NGỌC HÀ 58

 Generally limited to metals with low metal

PGS.TS. NGUYỄN NGỌC HÀ 59

Smoother cavity surface permits easier flow of

PGS.TS. NGUYỄN NGỌC HÀ 63

 More expensive metal pattern

 Difficult to justify for small quantities

PGS.TS. NGUYỄN NGỌC HÀ 64

PGS.TS. NGUYỄN NGỌC HÀ 66

PGS.TS. NGUYỄN NGỌC HÀ 67

 Many processing steps are required

 Relatively expensive process

PGS.TS. NGUYỄN NGỌC HÀ 69

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