CASTING
Casting is a process of producing goods by solidification (liquid melt)
through heat withdrawing. When melting (molten metal) material losses
heat, then it becomes solid. The process of solidification is called casting,
then the product is called cast.
PROCESS OF CASTING
The general process flow sheet for casting production is shown in Fig.1. the
steps are described below;
Casting Design
Drawing
Pattern Making
Moulding Melting
Pouring
Fettling
Inspection
Fig 1. The general process flow-sheet for casting
1
Step 1: A design of the casting is made. This may involve discussion
between design engineer and foundry engineer to evolve a good design at a
minimum cost of casting.
Step 2: A suitable drawing of the component is prepared. A detailed pattern
drawing should be made (indicate the surfaces to be machined and the
tolerances).
Step 3: A pattern is made. Pattern may be of wood, aluminum or other
metals, or plastic. Pattern has slightly different dimensions from the
component drawing due to “pattern allowances”.
Step 4: Using patterns, with cores if necessary, a mould is prepared. For
sand casting methods, specially prepared sands are used. For permanent
mould or die castings, metal moulds or dies are required. (Sand moulds are
destroyed while the casting is removed).
Step 5: Melting and Pouring: The metal is melted in a suitable furnace,
alloying additions are made, composition is adjusted and adequate pouring
temperature is attained. Then the metal is transferred to ladles and
subsequently poured into moulds.
Step 6: Fettling: After the casting has cooled, it is taken out of the mould.
Unwanted portions such as sprue, runners and risers are cut and removed.
The surface of the casting is cleaned.
Step 7: The casting may require certain heat treatment. Then it is inspected.
Inspectors check the dimensions, mechanical properties or pressure-
tightness, as required and may employ non-destructive tests.
Step 8: The approved castings are weighed, packed and shipped.
2
TYPES OF CASTING
1. SAND CASTING
They are made with moulding sand containing a surface binder like clay and
tempered with water. The control of sand parameters such as shape, size and
size distribution of sand grains, amount of binder and water, and mulling
time affect greatly the characteristics of the mould. The important
characteristics of the mould are strength, permeability to gases, resistance to
corrosion due to flowing metal and surfaces smoothness, they are also
influence by method of ramming which may be done by hand or by
machine.
ADVANTANGES OF SAND CASTING
Wide range of metals, sizes, shapes and low cost
Flexibility
Economical with very little wastage i.e the extra metal in each casting is
re-melted and re-used.
Cast melt is isotropic; it has the same physical/mechanical properties
along any direction
DISADVANTAGES OF SAND CASTING
Wide tolerance
It cannot be used for thin casting
It cannot be used for casting of material that have intricate shape
It have poor dimensional accuracy
Poor surface finish
Applications; door handles, locks, pumps, toy cars, wheels of cars, etc.
3
Other types of casting are;
2. Die casting
3. Expendable-pattern casting (lost foam process)
4. Plaster-mold casting
5. Ceramic mold casting
6. Investment casting (lost wax process)
7. Permanent mold casting
8. Centrifugal casting
ASSIGNMENT
1. What is metallurgy
2. Explain the branches of metallurgy
3. What is casting
4. Describe the steps involve in casting process
5. State the advantages and disadvantages of sand casting
6. Explain the different types of pattern allowance
7. Describe the properties of sand moulding
8. State the different casting defects and their causes
4
WELDING
Welding is the most important means of joining metals. It is an ancient process, but
continues to be refined and improved. Welding is used in almost all manufacturing
industries and for structural fabrication. For example, it is widely used for ship
building, construction of power plants, pipelines, chemical and hydrocarbon
process plants, and in automobile and aerospace manufacture.
ADVANTAGES AND DISADVANTAGES OF WELDING
Some of the advantages of welding are:
Welding is the most economical method to permanently join two metal
parts.
It provides design flexibility.
Welding equipment is not so costly.
It joins all the commercial metals.
Both similar and dissimilar metals can be joined by welding.
Portable welding equipment are available.
Some of the disadvantages of welding are:
Welding gives out harmful radiations and fumes.
Welding needs internal inspection.
If welding is not done carefully, it may result in the distortion of workpiece.
Skilled welding is necessary to produce good welding.
WELDING METHOD
Welding is a technique in which two materials are permanently joined together
through localized coalescence (fusing together) resulting from a suitable
combination of temperature, pressure and metallurgical conditions. The range of
temperatures and pressures which enable welding to be achieved has led to the
development of numerous welding processes. The various processes differ in the
manner in which temperature and pressure are combined and achieved. A further
5
important consideration is the cleanliness of the surface and possible
contamination during the welding process, and different methods utilize various
means of protecting or cleaning the surface. There are two broad categories, fusion
welding and solid-phase or non-fusion welding. Fusion welding processes uses
heat to melt the base metals. A fusion welding operation in which no filler metal
is added referred to as an autogenous weld, actual melting of the metal takes place
to form the bond. The following types of welding come under this category: Arc
welding, Resistance welding, Oxyfuel gas welding and Energy beam welding,
while in solid-phase (state) welding, the coalescence results from application of
pressure alone or a combination of heat and pressure. If heat is used, the
temperature is below the melting point of the metals being welded. No filler metal
is utilized in solid-state processes, bonding occurs due to diffusion of atoms. The
following types of welding come under this category: Diffusion welding, Friction
welding and Ultrasonic welding. Fusion welding is the most common process and
electric arc welding is by far the most important fusion welding method and there
is a variety of processes available.
