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Introduction To Metal Casting Processes and Their Classification

in this pdf there are metal casting process and their classifications

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rnawabi96
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12 views1 page

Introduction To Metal Casting Processes and Their Classification

in this pdf there are metal casting process and their classifications

Uploaded by

rnawabi96
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CASTING PROCESSES

Classification:

• Expendable Moulds:
o Made of sand, plaster, ceramics, etc. which are generally mixed with various binders, or bonding agents.
o These materials are refractories (they have the capability to withstand the high temperatures of molten metal).
o After the casting has solidified, the mould in these processes is broken up to remove the casting.
• Permanent Moulds:
o Designed in such a way that the casting can be easily removed, and the mould re-used for the next casting.
o Moulds are made of metals that maintain their strength at high temperatures and thus can be used repeatedly.
o Because metal moulds are better heat conductors than expendable moulds, the solidifying casting is subjected to
a higher rate of cooling, which in turn affects the microstructure and grain size within the casting.
• Composite Moulds:
o Made of two or more different materials, such as graphite and metal (combining the advantages of each material).
o Used in various casting processes to improve mould strength, cooling rates, and overall economics of the process.

METAL CASTING PROCESSES


What is Metal casting?
• Casting is one of the earliest metal-shaping methods known to human beings, which means pouring molten metal into a
refractory mould with the cavity of the shape to be made and allowing it to solidify. When solidified, the desired metal
object is taken out from the refractory mould either by breaking the mould or by taking the mould apart. The solidified
object is called casting. This process is called founding.
• Thus, in a single step, simple or complex shapes can be made from any metal that can be melted.
• The primary objective is to produce castings that are free from defects and that meet such requirements as strength,
dimensional accuracy, and surface finish.
• Metals most frequently cast are iron, steel, Al, brass, bronze, Mg, and certain Zn-alloys.
• Of these, iron, because of its fluidity, low shrinkage, strength, rigidity, and ease of control, is outstanding for its suitability
for casting and is used more than all other metals.
• Important factors in metal-casting operations include:
o Flow of molten metal into the mould cavity
o Heat transfer during solidification and cooling of the metal in the mould
o Influence of the type of mould material
o Solidification of the metal from its molten state

6-Basic processes involved in all casting methods:


• A mould cavity, having the desired shape and size and with due allowance for shrinkage of the solidifying metal, must be
produced.
• A suitable means must be available for melting the metal that is to be cast, providing not only adequate temperature but
also satisfactory quality and quantity at low cost.
• The molten metal must be introduced into the mould in such a manner that all air or gases in the mould, prior to pouring
or generated by the action of the hot metal upon the mould, will escape, and the mould will be completely filled.
• Provision must be made so that the mould will not cause too much restraint to the shrinkage that accompanies cooling after
the metal has solidified (otherwise, the casting will crack while its strength is low).
• It must be possible to remove the casting from the mould (expendable vs. permanent).
• After removal from the mould, finishing operations may need to be performed to remove extraneous material that is
attached to the casting as the result of the method of introducing the metal into the cavity, or is picked up from the mould
through contact with the metal.

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