Introduction

• Casting is a solidification process in

which molten metal is poured into a
mold and allowed to cool.
 Solidification Time

• Total solidification time TTS = time required for casting to

solidify after pouring
• TTS depends on size and shape of casting by
relationship known as Chvorinov's Rule n
 
V
TTS  C m  
A

where TTS = total solidification time; V = volume of the

casting; A = surface area of casting; n = exponent with
typical value = 2; and Cm is mold constant.
 Casting types
Expendable mold processes - mold is sacrificed to remove part
• Advantage: more complex shapes possible
• Disadvantage: production rates often limited by time to make
mold rather than casting itself
• 11.2 Expendable-mold, Permanent-patters
– Sand casting
• 11.3 Expendable-mold, Expendable-patters
– 11.3.1 Evaporative-pattern casting (lost-foam process)
– 11.3.2 Investment casting (lost-wax process)
Permanent-mold casting processes
• Advantage: higher production rates
• Disadvantage: geometries limited by need to open mold
– 11.4.5 Die casting
• HOT CHAMPER
• COLD CHAMPER
– 11.4.6 CENTRIFUGAL CASTING
 Two Categories of
Casting Processes

1. Expendable mold processes – use an expendable mold

which must be destroyed to remove casting
– Mold materials: sand, plaster, and similar
materials, plus binders
2. Permanent mold processes – use a permanent mold
which can be used to produce many castings
– Made of metal (or, less commonly, a ceramic
refractory material
 Casting of Metals
Process in which molten metal flows by gravity or other
force into a mold where it solidifies in the shape of the
mold cavity
• The term casting also applies to the part made in the
process
• Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
 Capabilities and Advantages of Casting
compared to other manufacturing processes

• 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 parts
• Some casting methods are suited to mass
production
 Disadvantages of Casting compared to other
manufacturing processes

• Different disadvantages for different casting

processes:
– Limitations on mechanical properties
– Poor dimensional accuracy and surface finish
for some processes; e.g., sand casting
– Safety hazards to workers due to hot molten
metals
– Environmental problems
 Overview of Casting Technology

• Casting is usually performed in a foundry

Foundry = factory equipped for making molds,
melting and handling molten metal, performing
the casting process, and cleaning the finished
casting
• Workers who perform casting are called
foundrymen
 The Mold in Casting
• Contains cavity whose geometry determines part
shape
– Actual size and shape of cavity must be slightly
enlarged to allow for shrinkage of metal during
solidification and cooling
– Molds are made of a variety of materials, including
sand, plaster, ceramic, and metal
 Use of a Core in the Mold Cavity
• The mold cavity provides the external surfaces
of the cast part
• In addition, a casting may have internal
surfaces, determined by a core, placed inside
the mold cavity to define the interior geometry of
part
• In sand casting, cores are generally made of
sand
 Gating System
Channel through which molten metal flows into
cavity from outside of mold
• Consists of a downsprue, through which metal
enters a runner leading to the main cavity
• At the top of downsprue, a pouring cup is often
used to minimize splash and turbulence as the
metal flows into downsprue
 Riser
Reservoir in the mold which is a source of liquid metal
to compensate for shrinkage of the part during
solidification
• The riser must be designed to freeze after the main
casting in order to satisfy its function
 The Pattern
A full-sized model of the part, slightly enlarged to account for
shrinkage and machining allowances in the casting
• Pattern materials:
– Wood - common material because it is easy to
work, but it warps
– Metal - more expensive to make, but lasts much
longer
– Plastic - compromise between wood and metal
 Heating the Metal

• Heating furnaces are used to heat the metal to

molten temperature sufficient for casting
• The heat required is the sum of:
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal to desired temperature
for pouring
 Pouring the Molten Metal
• For this step to be successful, metal must flow into all regions of the
mold, most importantly the main cavity, before solidifying
• Factors that determine success
– Pouring temperature
– Pouring rate
– Turbulence
 Shrinkage Allowance

• Patternmakers correct for solidification shrinkage

and thermal contraction by making the mold
cavity oversized
• Amount by which mold is made larger relative to
final casting size is called pattern shrinkage
allowance
• Casting dimensions are expressed linearly, so
allowances are applied accordingly
Sand casting
 Additional Steps After Solidification
• Trimming
• Removing the core
• Surface cleaning
• Inspection
• Repair, if required
• Heat treatment
 Expandable-Pattern Casting Process

Figure 11.11 Schematic illustration of the expandable-pattern casting process, also

known as lost-foam or evaporative casting.
Investment Casting
 Investment Casting (Lost Wax Process)

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 a less familiar definition of
"invest" - "to cover completely," which refers to coating of
refractory material around wax pattern
• It is a precision casting process - capable of producing
castings of high accuracy and intricate detail
 Advantages and Disadvantages of 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
– Many processing steps are required
– Relatively expensive process
 Permanent Mold Casting Processes
• Economic disadvantage of expendable mold casting: a
new mold is required for every casting
• In permanent mold casting, the mold is reused many
times
• The processes include:
– Basic permanent mold casting
– Die casting
– Centrifugal casting
 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 must be made of refractory
material, due to the very high pouring temperatures
Advantages and Limitations of Permanent Mold
Casting
• Advantages of permanent mold casting:
– Good dimensional control and surface finish
– More rapid solidification caused by the cold metal
mold results in a finer grain structure, so castings are
stronger
• Limitations:
– Generally limited to metals of lower melting point
– Simpler part geometries compared to sand casting
because of need to open the mold
– High cost of mold
 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
• Use of high pressure to force metal into die cavity is
what distinguishes this from other permanent mold
processes
 Molds for Die Casting
• Usually made of tool steel, mold steel, or maraging steel
• Tungsten and molybdenum (good refractory qualities)
used to die cast steel and cast iron
• Ejector pins required to remove part from die when it
opens
• Lubricants must be sprayed into cavities to prevent
sticking
 Die Casting Machines

• Designed to hold and accurately close two mold halves

and keep them closed while liquid metal is forced into
cavity
• Two main types:
1. Hot-chamber machine
2. Cold-chamber machine
 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 - 500 parts per hour not
uncommon
• Applications limited to low melting-point metals that do
not chemically attack plunger and other mechanical
components
• Casting metals: zinc, tin, lead, and magnesium
 Cold-Chamber Die Casting Machine
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 and Limitations of Die casting

• Advantages of die casting:

– Economical for large production quantities
– Good accuracy and surface finish
– Thin sections are possible
– Rapid cooling provides small grain size and
good strength to casting
• Disadvantages:
– Generally limited to metals with low metal
points
– Part geometry must allow removal from die
 Centrifuge Casting

Mold is designed with part cavities located away

from axis of rotation, so that molten metal
poured into mold is distributed to these cavities
by centrifugal force
• Used for smaller parts
• Radial symmetry of part is not required as in
other centrifugal casting methods