Casting

Casting
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 is most often used for making complex shapes that would
be otherwise difficult or uneconomical to make by other methods.
Heavy equipment like machine tool beds, ships' propellers, etc.

can be cast easily in the required size, rather than fabricating by
joining several small pieces. Casting is a 7,000-year-old process.
Range of products manufactured by using casting process

Household appliances
Construction equipment
Electrical components
Farming equipment
Defense weapons, tools, and equipment
Transportation: automobile, aerospace, railways, and shipping
Machining tools
Artistic and sculptural objects
PERMANENT MOLD OR GRAVITY DIE CASTING
A permanent mold casting makes use of a mold or metallic die
which is permanent. Molten metal is poured into the mold under
gravity only and no external pressure is applied to force the liquid
metal into the mold cavity. The metallic mold can be reused many
times before it is discarded or rebuilt.
These molds are made of dense, fine grained, heat resistant cast
iron, steel, bronze, anodized aluminum, graphite or other suitable
refractoriness. The mold is made in two halves in order to
facilitate the removal of casting from the mold.
This method is suitable for small and medium sized casting such
as carburetor bodies, oil pump bodies, connecting rods, pistons
etc.
It is widely suitable for non-ferrous casting.

Line diagram of A typical permanent mold
Advantages
No blow holes exist in castings produced by this method.
Close dimensional tolerance or job accuracy is possible to achieve on the

cast product.
Fast rate of production can be attained.
Disadvantages
The cost of metallic mold is higher than the sand mold. The process is
impractical for large castings.
The surface of casting becomes hard due to chilling effect.
Refractoriness of the high melting point alloys.

PRESSURE DIE CASTING
Unlike permanent mold or gravity die casting, molten metal is forced

into metallic mold or die under pressure in pressure die casting. The
pressure is generally created by compressed air or hydraulically means.
Air blown or goose neck type die casting setup

CENTRIFUGAL CASTING
In centrifugal casting process, molten metal is poured into a revolving mold
and allowed to solidify molten metal by pressure of centrifugal force. It is
employed for mass production of circular casting as the castings produced
by this process are free from impurities.
Due to centrifugal force, the castings produced will be of high density type
and of good strength. The castings produced promote directional
solidification as the colder metal (less temperature molten metal) is
thrown to outside of casting and molten metal near the axis or rotation.
The cylindrical parts and pipes for handling gases are most adoptable to
this process.
MOST COMMON DEFECTS IN THE CASTING PROCESS
casting defects that occur can be categorized as one of six types:
1) gas porosity, Blowholes Open Holes Pinholes
2) shrinkage defects, Open Shrinkage Defects Closed Shrinkage Defects

Warping
3) metallurgical defects, Hot or Hard Spots Hot Tears or Cracks
4) pouring metal defects, Misruns Cold Shut or Lap Slag Inclusion

Cold Shots
5) mold material defects, Cuts and Washes Fusion Swells Run Out
Drops Metal Penetration
Rat Tails, Buckles, and Veins
6) casting shape defects. Shift or Mismatch Flash, Fin, and Burrs

forming processes
Metal forming:
Large set of manufacturing processes in which the material is
deformed plastically to take the shape of the die geometry.
The tools used for such deformation are called die, punch etc.
depending on the type of process.
Plastic deformation: Stresses beyond yield strength of the workpiece

material is required.
Categories: Bulk metal forming, Sheet metal forming

Bulk forming:
It is a severe deformation process resulting in massive shape change.
The surface area-to-volume of the work is relatively small. Mostly done in
hot working conditions.
Rolling: In this process, the workpiece in the form of slab or plate is

compressed between two rotating rolls in the thickness direction, so that
the thickness is reduced. The rotating rolls draw the slab into the gap and
compresses it. The final product is in the form of sheet.
Forging: The workpiece is compressed between two dies containing

shaped contours. The die shapes are imparted into the final part.
Extrusion: In this, the workpiece is compressed or pushed into the die

opening to take the shape of the die hole as its cross section.
Wire or rod drawing: similar to extrusion, except that the workpiece is

pulled through the die opening to take the cross-section.

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Casting

Casting is a manufacturing process in which a liquid material is

The solidified part is also known as a casting, which is ejected or

Heavy equipment like machine tool beds, ships' propellers, etc.

Range of products manufactured by using casting process

It is widely suitable for non-ferrous casting.

No blow holes exist in castings produced by this method.

Close dimensional tolerance or job accuracy is possible to achieve on the

Fast rate of production can be attained.

The surface of casting becomes hard due to chilling effect.

Refractoriness of the high melting point alloys.

Unlike permanent mold or gravity die casting, molten metal is forced

Air blown or goose neck type die casting setup

casting defects that occur can be categorized as one of six types:

1) gas porosity, Blowholes Open Holes Pinholes

2) shrinkage defects, Open Shrinkage Defects Closed Shrinkage Defects

3) metallurgical defects, Hot or Hard Spots Hot Tears or Cracks

4) pouring metal defects, Misruns Cold Shut or Lap Slag Inclusion

6) casting shape defects. Shift or Mismatch Flash, Fin, and Burrs

Plastic deformation: Stresses beyond yield strength of the workpiece

Categories: Bulk metal forming, Sheet metal forming

Rolling: In this process, the workpiece in the form of slab or plate is

Forging: The workpiece is compressed between two dies containing

Extrusion: In this, the workpiece is compressed or pushed into the die

Wire or rod drawing: similar to extrusion, except that the workpiece is

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