Unit 2:

Special Casting Process

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 Introduction
• Casting is a manufacturing process in 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 processes involve the use of molten material, usually
metal. This molten material is then poured into a mould cavity
that takes the form of the finished part. The molten material
then cools, with heat generally being extracted via the mould,
until it solidifies into the desired shape.
Different Types of Casting Process
• Sand casting. •Centrifugal casting.
•Investment casting. •Gravity die casting.
•Die casting. •Vacuum die casting.
•Low pressure casting. •Squeezing die casting. 2
 Permanent mould casting
• Permanent mould casting is a process for producing a large
number of castings using a single reusable mould.
• The casting process simply involves pouring molten metal into a
mould where it cools and solidifies.
• The mould is then opened, the casting removed, and the mould
is reused.

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 Permanent mould casting
The advantages of Permanent mould casting includes:
• The main advantage of permanent mold casting is the fact that mold used in
the process, can be reused.
• The process is capable of producing more complex shapes and designs than
sand casting.
• The part casted has a good surface finish (as casted). The surface finish
delivered here is better than that of sand casted parts and components.
• Gravity die casting allows for a more precise control over dimensional
attributes than sand casting processes are able to.
• The casting process itself is highly repeatable and is well suited for high
volume production runs. The process can also be a highly automated one.
• Permanent mold casted parts have good mechanical properties, low
shrinkage and a low gas porosity.
• Parts have a homogeneous grain structure and the process itself produces
little scrap.

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 Permanent mould casting
The disadvantages of Permanent mould casting includes:
• A high tooling cost and a long set-up time.
• The permanent mold casting process is, in general, limited to smaller
castings.
• Because of the high tooling cost involved, a high production volume is needed
in order to make this process and economically viable manufacturing option.
• The higher the pouring temperature of the molten metal, the shorter the life
of the mold.

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 Permanent mould casting
The Limitations of Permanent mould casting includes:
• Only materials with lower melting temperatures can be used in the process.
• While cast iron parts are manufactured using this process, the high melting
point of cast iron does have a negative (or ‘wearing’) effect on the mold used.
• Part geometry is limited with this process as the mold needs to open and
close.
• This particular casting process becomes a less viable option when compared
to sand casting in cases where three or more sand cores are required.

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 Slush casting
Introduction:
• Slush casting is a variant of permanent molding casting to create a hollow
casting or hollow cast. In the process the material is poured into the mold
and allowed to cool until a shell of material forms in the mold. The remaining
liquid is then poured out to leave a hollow shell.
• Slush casting is a lasting process in which hollow casting is produced, with
inverting the mold after fractional freezing at surface to drain out liquid metal
in center.
• Solidification start at mold walls because they are comparatively cool and it progress in
excess of time toward middle of casting.
• Thickness of case is controlled through
length of time allowable before draining.
• Slush casting is use to create statues, lamp
pedestals, and toys out of low melting
point metals for example zinc, lead, and
tin.
• In these objects the outside form is
important but strength and interior
geometry of casting are small
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considerations.
 Slush casting
Advantages of slush casting:
• Range of elefantly planned casting can casted for decorative and ornamental
use.
• The preferred thickness can achieve through pouring the left over molten
metal
• Slush casting is use to make hollow parts with no the use of cores.
• Good surface finishes and good surface detail
• Reusable mold and fast cooling rates.

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 Slush casting
Disadvantages and Limitations of slush casting:
• Casting wall thickness can vary
• Lower melting point alloys
• Variable wall thickness
• Requires manual labor
• Time consuming

The applications of Slush Casting Process are as follows:

• Slush Casting Process is used to produce Gold Jewellery.
• It is used to manufacture the lamp’s components and hallow parts.
• Slush Casting is mainly used to manufacture brass materials items.

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 Die casting
• Die casting is an automated casting process that forces liquid
metal under high pressure (150 to 1200bar) into a mold cavity at
a high filling speed.
• This type of casting offers uniform quality to the component
produced.
• It is typically used when a high volume of production and when
quality, a consistent part is needed.
• It is known as one of the quickest and most economical casting
processes.
• And can produce a hundred of thousands casting of same item
using one mold, offering equal quality to the items.
• the die casting process is suitable for multiple and mass
production of components.
• It is better and faster than sand casting, due to the demolition of
mold when bringing out the casting. 10
 Die casting
Advantages die casting
• It offers accurate dimension and a good surface finish, helping to eliminate
post finishing
• It can be fully automated
• One of its greatest advantages is that one mold can be repeatedly used for
the same production.
• It offers a fast production rate
• Casting has long service life and close tolerance
• It is economical
• It is used for casting a wide range of complex application
Some other advantages die casting offers to the product properties
• Good processing properties
• Offers high electrical conductivity
• It has high corrosion resistance
• High strength and hardness
• High thermal conductivity
• Good EMF/RFI isolation
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Die casting
Disadvantages die casting
Despite the great advantages, die casting still offers some
disadvantages that can be avoided and overlook. The following
are:
• High die cast
• Gasses entrapped in form of porosity
• Metals and alloys with a high melting point cannot be applicable
• Too long lead time
• Smaller production runs may reduce the cost-effectiveness

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Die casting
Application of die casting
• The applications of die casting are most suitable for casting
medium-sized parts with complex details.
• The technique is often performed on nonferrous metals like
magnesium, aluminum, etc.
• Die casting is one of the largest casting methods that is used to
manufacture consumer, commercial and industrial products like
automobiles, toys, parts of the sink faucet, connector housing,
gears, etc.

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 Centrifugal casting
Introduction
• It works on basic principle of centrifugal force on a rotating
Component.
• In this process, a mould is rotated about its central axis when
the molten metal is poured into it.
• A centrifugal force acts on molten metal due to this rotation,
which forces the metal at outer wall of mould.
• The mould rotates until the
whole casting solidifies.
• The slag oxide and other
inclusion being lighter, gets
separated from metal and
segregate towards the center

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Centrifugal casting
Advantages of Centrifugal Casting
• It provides dense metal and high mechanical properties.
• Unidirectional solidification can obtain up to a certain
thickness.
• It can use for mass production.
• No cores are required for cast hollow shapes like tubes etc.
• Gating system and runner are totally eliminated.
• All the impurity like oxide or other slag particles, segregated at
center from where it can easily remove.
• It required lower pouring temperature thus save energy.
• Lower casting defects due to uniform solidification.

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Centrifugal casting
Disadvantages of Centrifugal Casting

• Limited design can be cast. It can cast only symmetrical

shapes.
• High equipment or setup cost.
• It is not suitable for every metal.
• Higher maintenance required.
• High skill operator required.
• In this casting process, solidification time and temperature
distribution is difficult to determine.

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Centrifugal casting
Application of Centrifugal Casting
• It is widely used in aircraft industries to cast rings, flanges
and compressor casting.
• It is used for cast Steam turbine bearing shell.
• Roller for steel rolling mill is another example of centrifugal
casting.
• It is used in automobile industries to cast gear blank, cylindrical
liners, piston rings etc.
• It is used to cast bearings.
• This process used to cast switch gear components used in
electronic industries.

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 Investment Casting
Introduction
• Investment casting, also known as precision casting or lost-wax
casting, is a manufacturing process in which a wax pattern is
used to shape a disposable ceramic mold.
• A wax pattern is made in the exact shape of the item to be cast.
This pattern is coated with a refractory ceramic material.
• Investment casting is so named because
the process invests (surrounds) the
pattern with refractory material to
make a mould, and a molten substance
is cast into the mold.

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 Investment Casting
Advantages of Investment Casting
• It offers a smooth surface finish
• Ability to produce a versatile and intricate finish
• It offers accurate dimension
• One of the greatest advantages of investment casting is that it
offers good and quality integrity to the casting. and
• Ability to produce casting with at least 1000 pounds weight.

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 Investment Casting
Disadvantages of Investment Casting
• Individual pattern is required for each casting.
• Limited casting dimensions.
• Relatively high cost (tooling cost, labor cost).

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 Investment Casting
Applications of Investment Casting
In the early stage, it was used by ancient Chinese and Egyptian
culture to create artwork. Not until the development of the jet
turbine engine at the end of world war II. Investment casting became
an enabling technology in most industries today, their applications
include:
• Aerospace and defense
• Power generation
• Automotive
• Oil and gas
• Space exploration
• Medical / orthopedics
• Agriculture
• Construction
• Commercial and consumer products. 21
 Mercasting / mercast process
Introduction
• Mercasting / mercast process is an improvement in precision
investment casting.
• In this manufacturing process, the pattern is made of mercury is
used to make mould.
• The mercury pattern is formed in a special aluminium mould. At
normal room temperature, the mercury is filled into the master
mould.
• Then the whole unit is cooled to a temperature below -38°C,
eventually the mercury gets solidify.
• The frozen mercury pattern is then removed from the master
mould and dipped into series of special slurries to form a harder
ceramic shell around them.
The temperature the mercury then allow to rise, the liquefied
mercury then retrieved from mould.
• The obtained mould is then used for investment casting. 22
 Mercasting / mercast process
Advantages of Mercasting / mercast process
• Excellent quality. It gives better surface finish.
• Mercury did not expand when it changed from solid form to liquid
form. So there is no any unwanted stress inside the mould during
pattern removal by melting.
• Mercury can flow into very thin sections of the master mould,
hence form a very detailed pattern.
• It gives close tolerance. Usually the mercasted shape does not
need further finishing process.
• The mercury can be reused to making the Pattern again.

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 Mercasting / mercast process
Disadvantages of Mercasting / mercast process
• Mercast process is expensive
• Pattern must be kept at low temperature; it is not desirable in
common foundry operation.
• Mercury is hazardous to health.
• Time-consuming process.

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 Continuous Casting
Introduction
• Continuous casting (CC) has been widely
accepted as the most important
production process in the steel industry.
• In the casting process, molten steel from
the ladle flows through the tundish into a
mould.
• Within the mould, the molten steel
freezes against the water-cooled copper
mould walls forming a solid shell.

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 Continuous Casting
• Molten metal from an induction furnace is fed directly
into a mold with the required shape (1).
• The molten metal enters the die through a series of
holes in the upper portion of the mold. Heat is extracted
by the water-cooled jacket surrounding the mold, and
the metal solidifies. The molten metal above the die acts
as a riser keeping the die filled and preventing the
formation of shrinkage cavities in the required finished
form: bar, tube or special shape (2).
• Solidification occurs in the die and then the solidified
metal casting exits through the bottom of the die by
means of a continuous process of short intermittent
extractions performed by a mechanical device (3).
• The product is withdrawn at controlled increments and
speed until the production length is met (4).
• Lengths are cut off by a traveling saw which moves with
the cast shape. The standard length for continuous cast
material is 144 inches (5).

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 Continuous Casting
Advantages of Continuous Casting
• Ability to cast regular shapes and certain irregular configurations in long
tubular form, which is difficult for other casting methods.
• Continuous cast bars require appreciably less machining stock.
• Continuous cast material is consistently dense and homogeneous in structure,
and therefore well-suited for pressure applications.
• Straight, true, and concentric product for high speed bar machines.
• Many suppliers maintain stock sizes for ready availability to distributors and
others requiring full lengths.
• If the shape is optimized, the clean-up stock required on continuous cast
material is often less than that needed for parts produced with other casting
processes. Stock of 1/32 to 3/32 inches per side depending on the casting size
is normally adequate.
• Continuous castings have an inherent advantage in mechanical properties over
other methods because of the chilling and the excellent feeding of molten
metal during solidification.
• Continuous castings perform well under pressure.
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 Continuous Casting
Disadvantages and Limitations of Continuous Casting
• There are a few limitations to consider when looking at
continuous casting. The biggest is the cost of setup.
• Due to both the high cost of creating a mold and the time spent
setting up the machine for each project, it is not practical to use
this method for small quantities or for special shapes of a
product.
• It also isn’t economical to use this method with special metal
alloys in smaller quantities.
• Another thing to consider is the shapes that can be cast.
• Continuous casting is limited to more simple shapes that have a
stable cross-section. This method is not a good option for some
of the more tedious, difficult casting projects

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Casting Defects
Classification according to the source of defects:-
A) Metallurgical defects : Porosity, sinks, inclusion, dross,
soldering.
B) Defects due to heat: Hot tears, cold shut, thermal fatigue.
C) Mechanically induced defects: Surface marks, bending,
undercuts

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 Casting Defects
Gas porosity: Gas porosity in casting is due to presence of gas which is in the form of
trapped air, moisture from water based die lubricant, dissolved hydrogen in air.
When the pouring of metal starts the air which is present in the cavity before pouring
is compressed and the pressure rises. It forms the bubbles after it has cooled.

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 Casting Defects
Shrinkage: Porosity Shrinkage porosity is one of the most common defects to
rejection of aluminum casting. It can be described as internal cracks in casting which
comes from several sources.

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 Casting Defects
Sinks Sinks form when there is presence of sub-surface cavity. A sink is depression
impacting of surface of part that does not mimic the mould surface. Sinks are often
visible because they reflects light.

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 Casting Defects
Soldering Soldering is one of the main and major casting defects in aluminum die
casting process. Soldering occurs when molten aluminum sticks the surface of die
steel and remain there after the ejection of casting. Soldering occurs after just few
casting cycle.

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Thank You

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