Manufacturing Processes

Lecture 6: Metal Casting Processes

Queen Tannous Spring 2025

 Lecture outline

• Sand Casting
• Other Expendable Mold Casting Processes
• Permanent Mold Casting Processes
• Foundry Practice
• Casting Quality
• Metals for Casting
• Product Design Considerations

Chapter 6: Metal Casting Processes

Two Categories of Casting Processes
• Expendable mold processes - mold is sacrificed to
remove part
• Advantage: more complex shapes possible

• Disadvantage: production rates often limited by the time to make

mold rather than casting itself

• Permanent mold processes - mold is made of metal and

can be used to make many castings
• Advantage: higher production rates
• Disadvantage: geometries are limited by the need to open the mold

Chapter 6: Metal Casting Processes

Overview of Sand Casting
• Most widely used casting process, accounting for a
significant majority of total tonnage cast

• Nearly all alloys can be sand casted, including metals with

high melting temperatures, such as steel, nickel, and
titanium

• Castings range in size from small to very large

• Production quantities from one to millions

• (Sand melting temperature around 1700°C)

Chapter 6: Metal Casting Processes

Sand Casting Sample

Sand casting for an

industrial pump. Holes and
surfaces have been
machined
(courtesy of George E. Kane
Manufacturing Technology
Laboratory, Lehigh University)

Chapter 6: Metal Casting Processes

Steps in Sand Casting
1. Pour the molten metal into sand mold

2. Allow time for metal to solidify

3. Break up the mold to remove casting

4. Clean and inspect casting (Separate gating and riser system)

5. Heat treatment of casting is sometimes required to

improve metallurgical properties

Chapter 6: Metal Casting Processes

Making the Sand Mold
• The cavity in the sand mold is formed by packing sand
around a pattern, then separating the mold into two
halves and removing the pattern

• The mold must also contain gating and riser system

• If casting is to have internal surfaces, a core must be

included in mold

• A new sand mold must be made for each part produced

Chapter 6: Metal Casting Processes

The Pattern
• 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 fabricate, but lasts longer
• Plastic: compromise between wood and metal

Chapter 6: Metal Casting Processes

Types of Patterns
Types of patterns used in sand casting: (a) solid pattern,
(b) split pattern, (c) match-plate pattern, (d) cope and
drag pattern

Chapter 6: Metal Casting Processes

Core
• Full-scale model of interior surfaces of part

• Inserted into mold cavity prior to pouring

• The molten metal flows and solidifies between the mold

cavity and the core to form the casting's external and
internal surfaces

• May require supports to hold it in position in the mold

cavity during pouring, called chaplets

Chapter 6: Metal Casting Processes

Core in Mold
(a) Core held in place in the mold cavity by chaplets,
(b) possible chaplet design, (c) casting

Chapter 6: Metal Casting Processes

Sand Casting Production Sequence
Production sequence in sand casting, including pattern-
making and mold-making

Chapter 6: Metal Casting Processes

Desirable Mold Properties
• Strength: to maintain shape and resist erosion
• Permeability: to allow hot air and gases to pass
through voids in sand
• Thermal stability: to resist cracking on contact with
molten metal
• Collapsibility: ability to give way and allow casting
to shrink without cracking the casting
• Reusability: can sand from broken mold be reused to
make other molds?

Chapter 6: Metal Casting Processes

Foundry Sand
• Silica (SiO2) or silica mixed with other minerals

• Good refractory properties - for high temperatures

• Small grain size for better surface finish on part

• Large grain size is more permeable, allowing gases to

escape during pouring

• Irregular grain shapes strengthen molds due to

interlocking, compared to round grains
• Disadvantage: interlocking reduces permeability

Chapter 6: Metal Casting Processes

Binders Used with Foundry Sand
• Sand is held together by a mixture of water and bonding
clay
• Typical mix: 90% sand, 3% water, and 7% clay

• Other bonding agents also used in sand molds:

• Organic resins (e g , phenolic resins)
• Inorganic binders (e g , sodium silicate and phosphate)

• Additives are sometimes combined with the mixture to

increase strength and/or permeability

Chapter 6: Metal Casting Processes

Types of Sand Mold
• Green-sand molds: mixture of sand, clay, and water. “Green"
means mold contains moisture at time of pouring.

• Dry-sand mold: organic binders rather than clay. Mold is baked

to improve strength

• Skin-dried mold: drying mold cavity surface of a green-

sand mold to a depth of 10 to 25 mm, using torches or
heating lamps

Chapter 6: Metal Casting Processes

Buoyancy in a Sand Casting
Operation
• During pouring, buoyancy of the molten metal tends to displace the
core, which can cause casting to be defective
• Force tending to lift core = weight of displaced liquid minus the
weight of core itself
𝑭𝒃 = 𝑾𝒎 − 𝑾𝑪
where Fb = buoyancy force;
Wm = weight of molten metal displaced; and
Wc = weight of core

Chapter 6: Metal Casting Processes

Other Expendable Mold Processes

• Shell Molding

• Vacuum Molding

• Expanded Polystyrene Process

• Investment Casting

• Plaster Mold and Ceramic Mold Casting

Chapter 6: Metal Casting Processes

Shell Molding
Casting process in which the mold is a thin shell of sand
held together by thermosetting resin

Steps:
1) A metal pattern is heated and placed over a box containing sand
mixed with TS resin

Chapter 6: Metal Casting Processes

Steps in Shell Molding

2) Box is inverted so that

sand and resin fall onto the 3) Box is repositioned so
hot pattern, causing a loose uncured
layer of the mixture to particles drop away
partially cure on the
surface to form a hard
shell

Chapter 6: Metal Casting Processes

Steps in Shell Molding

4) Sand shell is heated in 5) Shell mold is

oven for several
minutes to complete stripped from
curing pattern

Chapter 6: Metal Casting Processes

Steps in Shell Molding

6) Two halves of the shell mold

are assembled, supported by 7) Finished casting with
sand or metal shot in a box, sprue removed
and pouring is accomplished

Chapter 6: Metal Casting Processes

Shell Molding – Pros and Cons
Advantages:
• Smoother cavity surface permits easier flow of molten metal and
better surface finish
• Good dimensional accuracy
• Mold collapsibility minimizes cracks in casting
• Can be mechanized for mass production

Disadvantages:
• More expensive metal pattern
• Difficult to justify for small quantities

Chapter 6: Metal Casting Processes

Vacuum Molding

• Uses sand mold held together by vacuum pressure rather

than by a chemical binder
• The term "vacuum" refers to mold making rather than
casting operation itself
• Developed in Japan around 1970

Chapter 6: Metal Casting Processes

Vacuum Molding
Vacuum Molding: Pros and Cons
Advantages:
• Easy recovery of the sand, since no binders

• Sand does not require mechanical reconditioning done when

binders are used
• Since no water is mixed with sand, moisture-related defects are
avoided

Disadvantages:
• Slow process
• Not readily adaptable to mechanization

Chapter 6: Metal Casting Processes

Expanded Polystyrene Process
• Uses a mold of sand packed around a polystyrene foam
pattern which vaporizes when molten metal is poured into
mold

• Other names: lost-foam process, lost pattern process,

evaporative-foam process, and full-mold process

• Polystyrene foam pattern includes sprue, risers, gating

system, and internal cores (if needed)

• Mold does not have to be opened into cope and drag

sections
Chapter 6: Metal Casting Processes
Steps in Expanded Polystyrene
Process

1) Polystyrene foam pattern 2) Foam pattern is placed

is coated with refractory in mold box, and sand
compound is compacted around
the pattern

Chapter 6: Metal Casting Processes

Steps in Expanded Polystyrene
Process

3) Molten metal is poured into the portion of the pattern that forms
the pouring cup and sprue. As the metal enters the mold, the
polystyrene foam is vaporized ahead of the advancing liquid, thus
filling the mold cavity

Chapter 6: Metal Casting Processes

Expanded Polystyrene Process
Advantages:
• Pattern need not be removed from the mold

• Simplifies and speeds mold-making, because two mold halves are

not required as in a conventional green-sand mold

Disadvantages:
• A new pattern is needed for every casting

• Economic justification of the process is highly dependent on

cost of producing patterns

Chapter 6: Metal Casting Processes

Expanded Polystyrene Process
Applications:

• Mass production of castings for automobile engines

• Automated and integrated manufacturing systems are

used to
1. Mold the polystyrene foam patterns
2. Feed them to the downstream casting operation

Chapter 6: Metal Casting Processes

Expanded Polystyrene Casting
Sample
Aluminum engine head produced

Chapter 6: Metal Casting Processes

Investment Casting (Lost Wax
Process)
• A pattern made of wax is coated with a refractory material to make
the 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

Chapter 6: Metal Casting Processes

Steps in Investment Casting

1) Wax patterns are produced

2) Several patterns are
attached to a sprue to form a
pattern tree

Chapter 6: Metal Casting Processes

Steps in Investment Casting

3) Pattern tree is coated with a thin layer of refractory material

4) Full mold is formed by covering the coated tree with
sufficient refractory material to make it rigid

Chapter 6: Metal Casting Processes

Steps in Investment Casting

5) Mold is held in an inverted position and heated to melt the wax and
permit it to drip out of the cavity
6) Mold is preheated to a high temperature, the molten metal is
poured, and it solidifies

Chapter 6: Metal Casting Processes

Steps in Investment Casting

7) Mold is broken away

from the finished
casting and the parts
are separated from the
sprue

Chapter 6: Metal Casting Processes

 Investment Casting Sample

One-piece compressor
stator with 108 separate
airfoils made by
investment casting

(courtesy of Alcoa Howmet)

Chapter 6: Metal Casting Processes

Investment Casting
Advantages:
• Parts of great complexity and intricacy can be cast
• Close dimensional control and good surface finish
• Wax can usually be recovered for reuse

• This is a net shape process- additional machining is not normally

required

Disadvantages:
• Many processing steps are required
• Relatively expensive process

Chapter 6: Metal Casting Processes

Plaster Mold Casting
• Similar to sand casting except mold is made of plaster of Paris
(gypsum - CaSO4-2H2O)
• In mold-making, plaster and water mixture is poured over plastic or
metal pattern and allowed to set
• Wood patterns not generally used due to extended contact with
water
• Plaster mixture readily flows around pattern, capturing its fine
details and good surface finish

Chapter 6: Metal Casting Processes

Plaster Mold Casting – Pros and
Cons
Advantages:
• Good accuracy and surface finish
• Capability to make thin cross sections

Disadvantages:
• Mold must be baked to remove moisture
• Moisture can cause problems in casting

• Mold strength is lost if over-baked

• Plaster molds cannot stand high temperatures- Limited to lower
melting point alloys (maximum 1200°C)

Chapter 6: Metal Casting Processes

Ceramic Mold Casting
• Similar to plaster mold casting except that mold is made of
refractory ceramic material that can withstand higher
temperatures than plaster

• Can be used to cast steels, cast irons, and other high-

temperature alloys (1162-1240℃ mid-range, 2200°C for
advanced ceramics)

• Applications similar to those of plaster mold casting except for the

metals cast

• Advantages (good accuracy and finish) also similar

Chapter 6: Metal Casting Processes

Permanent Mold Casting Processes
• Economic disadvantage of expendable mold casting:
o A new mold is required for every casting

• In permanent mold casting, the mold is reused many

times

• Processes include:
o Basic permanent mold casting

o Die casting

o Centrifugal casting

Chapter 6: Metal Casting Processes

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

Chapter 6: Metal Casting Processes

Steps in Permanent Mold Casting

1) Mold is preheated and coated for lubrication and heat

dissipation

Chapter 6: Metal Casting Processes

Steps in Permanent Mold Casting

2) Cores (if any are used)

3) Molten metal is poured into
are inserted and mold is
the mold, where it solidifies
closed

Chapter 6: Metal Casting Processes

Steps in Permanent Mold Casting

4) Mold is opened

Chapter 6: Metal Casting Processes

Permanent Mold Casting– Pros and
Cons
Advantages:
• Good dimensional control and surface finish

• Rapid solidification caused by 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

Chapter 6: Metal Casting Processes

Permanent Mold Casting
Applications
• Due to high mold cost, process is best suited to high
volume production and can be automated accordingly

• Typical parts: automotive pistons, pump bodies, and

certain castings for aircraft and missiles

• Metals commonly cast: aluminum, magnesium, copper-base

alloys, and cast iron
• Unsuited to steels because of very high pouring temperatures

Chapter 6: Metal Casting Processes

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

Chapter 6: Metal Casting Processes

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

Chapter 6: Metal Casting Processes

Hot-Chamber Die Casting
Metal is melted in a container, and a piston injects liquid
metal under high pressure into the die

Hot-chamber die
casting cycle:

1) With die closed and plunger

withdrawn, molten metal flows into
the chamber

Chapter 6: Metal Casting Processes

Hot-Chamber Die Casting

2) Plunger forces metal in

chamber to flow into
die, maintaining
pressure during cooling
and solidification.

Chapter 6: Metal Casting Processes

Hot-Chamber Die Casting

3) Plunger is withdrawn,
die is opened, and
casting is ejected

Chapter 6: Metal Casting Processes

Hot-Chamber Die Casting
• 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

Chapter 6: Metal Casting Processes

Cold-Chamber Die Casting Cycle
Molten metal is poured into unheated chamber from external melting
container, and a piston injects metal under high pressure into die cavity

1) With die closed and ram withdrawn, molten metal

is poured into the chamber

Chapter 6: Metal Casting Processes

Cold-Chamber Die Casting Cycle

2) Ram forces metal to flow

3) Ram is withdrawn, die
into die, maintaining
is opened, and part is
pressure during cooling
ejected
and solidification

Chapter 6: Metal Casting Processes

Cold-Chamber Die Casting Machine

• High production but not usually as fast as hot-chamber

machines because of pouring step

• Casting metals: aluminum, brass, and magnesium alloys

• Advantages of hot-chamber process favor its use on

low melting-point alloys (zinc, tin, lead)

Chapter 6: Metal Casting Processes

Molds for Die Casting
• Usually made of tool steel, mold steel, or maraging steel
(high strength, toughness and ductility)

• 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 onto cavity surfaces to

prevent sticking

Chapter 6: Metal Casting Processes

Die casting sample

A die casting that measures

about 400 mm diagonally
for a truck cab floor
(courtesy of George E. Kane
Manufacturing Technology
Laboratory)

Chapter 6: Metal Casting Processes

Die Casting: Advantages and
Limitations
Advantages:
• Economical for large production quantities
• Good accuracy and surface finish
• Thin sections possible
• Rapid cooling means small grain size and good strength in casting

Disadvantages:
• Generally limited to metals with low metal points
• Part geometry must allow removal from die

Chapter 6: Metal Casting Processes

Squeeze Casting
• Combination of casting and forging in which a molten metal is poured
into a preheated lower die, and the upper die is closed to create the
mold cavity after solidification begins
• Differs from usual closed-mold casting processes in which die halves
are closed before introduction of the molten metal
• Compared to conventional forging, pressures are less and finer
surface details can be achieved

Chapter 6: Metal Casting Processes

Centrifugal Casting
• A family of casting processes in which the mold is rotated
at high speed so centrifugal force distributes molten
metal to outer regions of die cavity

• The group includes:

• True centrifugal casting
• Semicentrifugal casting
• Centrifuge casting

Chapter 6: Metal Casting Processes

True Centrifugal Casting
• Molten metal is poured into rotating mold to produce a
tubular part

• In some operations, mold rotation commences after

pouring rather than before

• Parts: pipes, tubes, bushings, and rings

• Outside shape of casting can be round, octagonal,

hexagonal, etc, but inside shape is (theoretically)
perfectly round, due to radially symmetric forces

Chapter 6: Metal Casting Processes

True Centrifugal Casting

Setup for true centrifugal casting

Chapter 6: Metal Casting Processes

Semicentrifugal Casting
• Centrifugal force is used to produce solid castings rather
than tubular parts

• Molds use risers at center to supply feed metal

• Density of metal in final casting is greater in outer

sections than at center of rotation

• Often used on parts in which center of casting is machined

away, thus eliminating the portion where quality is lowest
• Examples: wheels and pulleys

Chapter 6: Metal Casting Processes

Semicentrifugal Casting

Chapter 6: Metal Casting Processes

Centrifuge Casting

(a) The process and (b) one of the parts cast

Chapter 6: Metal Casting Processes

Centrifuge Casting
• Mold is designed with part cavities located away from
axis of rotation, so 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

Chapter 6: Metal Casting Processes

Furnaces for Casting Processes

• Furnaces most commonly used in foundries:

• Cupolas
• Direct fuel-fired furnaces
• Crucible furnaces
• Electric-arc furnaces
• Induction furnaces

Chapter 6: Metal Casting Processes

Cupolas
• Vertical cylindrical furnace equipped with tapping spout
near base

• Used only for cast irons

• Although other furnaces are also used, the largest tonnage of
cast iron is melted in cupolas

• The "charge", consisting of iron, coke, flux, and any

alloying elements, is loaded through a charging door
located less than halfway up height of cupola

Chapter 6: Metal Casting Processes

Cupola for
melting cast iron

Chapter 6: Metal Casting Processes

Direct Fuel-Fired Furnaces
• Small open-hearth in which charge is heated by natural
gas fuel burners located on side of furnace

• Furnace roof assists heating action by reflecting flame

down against charge

• At bottom of hearth is a tap hole to release molten metal

• Generally used for nonferrous metals such as copper-base

alloys and aluminum

Chapter 6: Metal Casting Processes

Direct Fuel-Fired Furnaces
Crucible Furnaces
• Metal is melted without direct contact with burning fuel mixture

• Sometimes called indirect fuel-fired furnaces

• Container (crucible) is made of refractory material or high-

temperature steel alloy

• Used for nonferrous metals such as bronze, brass, and alloys of zinc
and aluminum

• Three types used in foundries: (a) lift-out type, (b) stationary, (c)
tilting

Chapter 6: Metal Casting Processes

Three Types of Crucible Furnaces

(a) Lift-out crucible, (b) stationary pot- molten

metal must be ladled, and (c) tilting-pot furnace

Chapter 6: Metal Casting Processes

Electric-Arc Furnaces
• Charge is melted by heat generated from an electric arc
• High power consumption
• But electric-arc furnaces can be designed for high melting
capacity

• Used primarily for melting steel

Chapter 6: Metal Casting Processes

Induction Furnace
• Uses alternating current passing through a coil to
develop magnetic field in metal
• Induced current causes rapid heating and melting
• Electromagnetic force field also causes mixing action

• Since metal does not contact heating elements,

environment can be closely controlled to produce molten
metals of high quality and purity

• Common alloys: steel, cast iron, and aluminum

Chapter 6: Metal Casting Processes

 Induction Furnace

Chapter 6: Metal Casting Processes

Ladles

Two common types of ladles to transfer molten metals

to molds: (a) crane ladle, and (b) two-man ladle

Chapter 6: Metal Casting Processes

Additional Steps After Solidification
• Trimming

• Removing the core

• Surface cleaning

• Inspection

• Repair, if required

• Heat treatment

Chapter 6: Metal Casting Processes

Trimming
• Removal of sprues, runners, risers, parting-line
flash, fins, chaplets, and any other excess metal
from the cast part
• For brittle casting alloys and when cross sections are
relatively small, appendages can be broken off
• Otherwise, hammering, shearing, hack-sawing, band-
sawing, abrasive wheel cutting, or various torch cutting
methods are used

Chapter 6: Metal Casting Processes

Removing the Core
• If cores have been used, they must be removed

• Most cores are bonded, and they often fall out of casting
as the binder deteriorates

• In some cases, they are removed by shaking the casting,

either manually or mechanically

• In rare cases, cores are removed by chemically

dissolving bonding agent

• Solid cores must be hammered or pressed out

Chapter 6: Metal Casting Processes

Surface Cleaning and Inspection
• Removal of sand from casting surface and otherwise
enhancing appearance of surface

• Cleaning methods: tumbling, air-blasting with coarse

sand grit or metal shot, wire brushing, buffing, and
chemical pickling

• Surface cleaning is most important for sand casting

• Defects are possible in casting, and inspection is needed

to detect their presence

Chapter 6: Metal Casting Processes

Heat Treatment
• Castings are often heat treated to enhance properties
• Reasons for heat treating a casting:
• For subsequent processing operations such as machining

• To bring out the desired properties for the application of the part
in service

Chapter 6: Metal Casting Processes

Casting Quality

• There are numerous opportunities for things to go

wrong in a casting operation, resulting in quality
defects in the product
• The defects can be classified as follows:
• General defects common to all casting processes
• Defects related to sand casting process

Chapter 6: Metal Casting Processes

General Defects: Misrun
A casting that has solidified before completely
filling mold cavity

Chapter 6: Metal Casting Processes

General Defects: Cold Shut
Two portions of metal flow together but there is a
lack of fusion due to premature freezing

Chapter 6: Metal Casting Processes

General Defects: Cold Shot

Metal splatters during pouring and solid globules

form and become entrapped in casting

Chapter 6: Metal Casting Processes

General Defects: Shrinkage Cavity
Depression in surface or internal void caused by
solidification shrinkage that restricts amount of
molten metal available in last region to freeze

Chapter 6: Metal Casting Processes

Sand Casting Defects: Sand Blow
Balloon-shaped gas cavity caused by release of mold
gases during pouring

Chapter 6: Metal Casting Processes

Sand Casting Defects: Pin Holes

Formation of many small gas cavities at or slightly

below surface of casting

Chapter 6: Metal Casting Processes

Sand Casting Defects: Penetration
When fluidity of liquid metal is high, it may penetrate
into sand mold or core, causing casting surface to
consist of a mixture of sand grains and metal

Chapter 6: Metal Casting Processes

Sand Casting Defects: Mold Shift

A step in the cast product at parting line caused by

sidewise relative displacement of cope and drag

Chapter 6: Metal Casting Processes

Foundry Inspection Methods
• Visual inspection to detect obvious defects such as
misruns, cold shuts, and severe surface flaws

• Dimensional measurements to insure that tolerances have

been met

• Metallurgical, chemical, physical, and other tests

concerned with quality of cast metal

Chapter 6: Metal Casting Processes

Metals for Casting

• Most commercial castings are made of alloys rather

than pure metals
• Alloys are generally easier to cast, and properties of product are
better

• Casting alloys can be classified as:

• Ferrous
• Nonferrous

Chapter 6: Metal Casting Processes

Ferrous Casting Alloys: Cast Iron
• Most important of all casting alloys

• Tonnage of cast iron castings is several times that of all

other metals combined

• Several types: (1) gray cast iron, (2) nodular iron, (3)
white cast iron, (4) malleable iron, and (5) alloy cast
irons

• Typical pouring temperatures  1400C (2500F),

depending on composition

Chapter 6: Metal Casting Processes

Ferrous Casting Alloys: Steel
• The mechanical properties of steel make it an
attractive engineering material

• The capability to create complex geometries makes

casting an attractive shaping process

• Difficulties when casting steel:

• Pouring temperature is high  1650C (3000F)
• At such temperatures, steel readily oxidizes, so molten metal must
be isolated from air
• Molten steel has relatively poor fluidity

Chapter 6: Metal Casting Processes

Nonferrous Casting Alloys:
Aluminum
• Generally considered to be very castable

• Low pouring temperatures due to low melting

temperature
• Pure Aluminum Tm = 660C (1220F)

• Properties:
• Light weight
• Range of strength properties by heat treatment
• Easy to machine

Chapter 6: Metal Casting Processes

Nonferrous Casting Alloys: Copper
Alloys
• Includes bronze, brass, and aluminum bronze

• Properties:
• Corrosion resistance
• Attractive appearance
• Good bearing qualities

• Limitation: high cost of copper

• Applications: pipe fittings, marine propeller blades, pump

components, ornamental jewelry

Chapter 6: Metal Casting Processes

Nonferrous Casting Alloys: Zinc
Alloys
• Very castable, commonly used in die casting

• Low pouring temperatures due to low melting temperature

• Pure zinc Tm = 419C (786F)

• Good fluidity for ease of casting

• Properties:
• Low creep strength, so castings cannot be subjected to prolonged
high stresses

Chapter 6: Metal Casting Processes

Product Design Considerations
• Geometric simplicity

• Although casting can be used to produce complex part

geometries, simplifying the part design usually improves
castability

• Avoiding unnecessary complexities:

• Simplifies mold-making
• Reduces the need for cores
• Improves the strength of the casting

Chapter 6: Metal Casting Processes

Product Design Considerations
• Corners on the casting

• Sharp corners and angles should be avoided, since they are

sources of stress concentrations and may cause hot tearing
and cracks

• Generous fillets should be designed on inside corners and

sharp edges should be blended

Chapter 6: Metal Casting Processes

Product Design Considerations
• Draft Guidelines
• In expendable mold casting, draft facilitates removal of
pattern from mold
• Draft = 1 for sand casting

• In permanent mold casting, purpose is to aid in removal of the

part from
the mold
• Draft = 2 to 3 for permanent mold processes

• Similar tapers should be allowed for solid cores

Chapter 6: Metal Casting Processes

Draft
Design change to eliminate need for using a core: (a)
original design, and (b) redesign

Chapter 6: Metal Casting Processes

Product Design Considerations
• Dimensional Tolerances and Surface Finish
• Dimensional accuracy and finish vary significantly,
depending on process
• Poor dimensional accuracies and finish for sand casting

• Good dimensional accuracies and finish for die casting and

investment casting

Chapter 6: Metal Casting Processes

Product Design Considerations
• Machining Allowances

• Almost all sand castings must be machined to

achieve the required dimensions and part features

• Additional material, called the machining allowance, is

left on the casting in those surfaces where machining is
necessary

• Typical machining allowances for sand castings are around

1.5 and 3 mm (1/16 and 1/4 in)

Chapter 6: Metal Casting Processes