CASE STUDY

FABRICATED MATERIAL
USED IN
CASTING PROCESS

NAME : GOWTHAM V
ROLL NO : 71762302081
SUBJECT : MANUFACTURING PROCESSES-I
SUBJECT CODE : 23ME313
DEPARTMENT : MECHANICAL ENGINEERING
FACULTY : Dr.G. SUGANYA PRIYADHARSHINI
DATE GIVEN : 16/07/2024
DATE OF SUBMISSION : 05/08/2024
CONTENTS

FABRICATED MATERIAL USED IN

CASTING PROCESS

1. BRASS HEX NUT

2. HEAT TREATMENT FURNACE
3. PIVOT HOUSING

• TYPE OF CASTING and WHY?

• TYPE OF MATERIAL and WHY?

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BRASS HEX NUT

For manufacturing brass hex

nuts, the common casting
method used is die casting.
This process involves injecting
molten brass into a mold or die
under high pressure. Die
casting is preferred for
producing small to medium-
sized parts with complex
shapes and tight tolerances,
making it ideal for components
like hex nuts.

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TYPE OF CASTING and WHY?

Die casting is the preferred method for manufacturing brass hex nuts due
to several compelling reasons:
1.Precision and Accuracy: Die casting produces parts with high
dimensional accuracy and tight tolerances. This is essential for hex
nuts, which need to fit precisely with bolts and other components.
2.Surface Finish: The process results in a smooth surface finish,
reducing the need for additional machining or finishing. This is
particularly important for parts like hex nuts, where surface quality can
affect performance and aesthetics.
3.High Production Efficiency: Die casting is a highly automated
process that allows for rapid production of large quantities of parts. This
makes it ideal for mass production of small to medium-sized
components like hex nuts, ensuring consistent quality and reducing
production costs. 4
TYPE OF MATERIAL and WHY?

Brass hex nuts are typically made from various grades

of brass, which is an alloy primarily composed of
copper and zinc. The specific composition can vary, but
common brass alloys used for hex nuts include:
1.C36000 (Free-Cutting Brass): Also known as C360
or CDA 360, this alloy contains about 60% copper,
3% lead, and 37% zinc. It is widely used for
machining operations due to its excellent
machinability, making it a popular choice for hex nuts.
2.C38500 (Architectural Bronze): This alloy, also
known as architectural bronze, contains about 57-
59% copper, 2.5-3.5% lead, and the balance zinc. It is
known for its good machinability and corrosion
resistance. 5
TYPE OF MATERIAL and WHY?

Brass is chosen for hex nuts due to its combination of favorable properties that
make it well-suited for this application:
1.Corrosion Resistance: Brass exhibits excellent resistance to corrosion,
particularly in environments where moisture or chemical exposure might
occur. This makes brass hex nuts suitable for both indoor and outdoor
applications, including marine and industrial settings.
2.Strength and Durability: Brass provides a good balance of strength and
ductility. Hex nuts made from brass are strong enough to withstand the
mechanical stresses of fastening applications while being durable over time.
3.Machinability: Brass, especially alloys like C36000 (Free-Cutting Brass), has
excellent machinability. This property allows for precise and efficient
manufacturing processes, including threading and forming, which are
essential for producing high-quality hex nuts.

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\HEAT TREATMENT FURNACE

Sand Casting: This is the most

prevalent method for
manufacturing large components
of heat treatment furnaces. Sand
casting involves creating a mold
from a sand mixture and pouring
molten metal into the cavity. It's
ideal for producing large, heavy
parts like furnace bodies, bases,
and covers due to its flexibility
and cost-effectiveness.

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TYPE OF CASTING and WHY?

. Sand Casting
Why:
• Size and Weight: Sand casting is ideal for producing
large and heavy parts, such as furnace bodies and
bases.
• Cost-Effectiveness: The molds used in sand casting
are relatively inexpensive to produce, making it cost-
effective for large parts.
• Versatility: Sand casting can be used with a wide range
of metals and alloys, making it suitable for various
furnace components.

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TYPE OF MATERIAL and WHY?

Specific Components and Their Material Choices:

• Furnace Body and Base: Typically made from gray or
ductile iron due to the need for a robust and stable
structure.
• Support Structures and Internal Framework: Often
made from cast steel or alloy steel for enhanced strength
and durability.
• Burners, Nozzles, and Other High-Temperature Parts:
Made from heat-resistant alloys like stainless steel or
nickel-based superalloys to withstand direct exposure to
high temperatures and corrosive gases.

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TYPE OF MATERIAL and WHY?

Why These Materials Are Chosen:

• Thermal Resistance: Heat treatment furnaces operate at
high temperatures, so materials must maintain their
integrity and mechanical properties under thermal stress.
• Mechanical Strength: The materials must support the
weight and structure of the furnace and withstand
mechanical forces without deforming or failing.
• Durability: The furnace components must resist wear,
oxidation, and corrosion to ensure a long operational life
with minimal maintenance.
• Cost-Effectiveness: While performance is critical, the cost
of materials and manufacturing processes also influences
material selection. Balancing performance with cost
efficiency is key in material choice for furnace components.
1
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PIVOT HOUSING

The type of casting used for

pivot housings often depends on
the required precision, size, and
production volume. Common
casting methods for pivot
housings include:

1
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TYPE OF CASTING and WHY?

Investment Casting (Lost-Wax Casting)

Why:
• Precision: Investment casting produces parts with
high dimensional accuracy and fine details, which is
ideal for the intricate shapes and tight tolerances of
pivot housings.
• Surface Finish: This method provides a smooth
surface finish, reducing the need for extensive post-
casting machining.
• Complex Geometries: Investment casting can
produce complex shapes that might be difficult to
achieve with other casting methods.

1
2
TYPE OF MATERIAL and WHY?

Steel
• Carbon Steel:
• High Strength: Carbon steel offers good strength
and hardness, making it suitable for high-load
applications.
• Cost: It is less expensive than alloy steels and
stainless steels, making it a cost-effective choice
for many applications.
• Alloy Steel:
• Enhanced Properties: The addition of elements
like chromium, nickel, and molybdenum improves
hardness, strength, and wear resistance, making
alloy steel suitable for demanding applications
where durability is critical. 1
3
TYPE OF MATERIAL and WHY?

Stainless Steel:
• Corrosion Resistance: Stainless steel’s
resistance to rust and corrosion makes it ideal for
environments where exposure to moisture,
chemicals, or other corrosive elements is a
concern.
• Strength: It provides a good balance of strength
and corrosion resistance, making it suitable for
many industrial and commercial applications.

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CONTENTS

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