Casting Processes Casting Processes: ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009 1

Casting Processes
ver. 1
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Types of Parts Made

Engine blocks Pipes Jewelry Fire hydrants Fi h d t
Complex, 3-D Complex 3 D shapes

Near net shape p Low scrap Relatively quick process Intricate shapes Large hollow shapes No limit to size Reasonable to good surface finish
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 3
Processes
Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification Slush Continuous
4
Metals processed by casting

Sand casting 60% Investment casting 7% g Die casting 9% Permanent mold casting 11% Centrifugal casting 7% Shell mold casting 6%
Breakdown of Castings
Ingots for bulk deformation processing 85% Cast to near net shape - 15%
Ingots
Iron or steel molds Water-cooled molds Water cooled Continuous casting
Shapes
Permanent mold (cavity)
die casting hot chamber cold chamber ld h b
Expendable Molds
sand shell slurry investment
lost wax lost foam
Shapes
Centrifugal
pipes spinning
Capabilities
Dimensions
sand casting - as large as you like small - 1 mm or so
Tolerances
0 005 in to 0 1 in 0.005 0.1
Surface finish
di casting 8 16 micro-inches (1 3 m) die ti 8-16 i i h (1-3 ) sand casting - 500 micro-inches (10-25 m)
Casting Steps
quick route from raw material to finished product
Melt metals Pour / force liquid into hollow cavity (mold) Cool / Solidify Remove Finish
Melting
Raw material (charge)
scrap alloying materials scrap,
Heat
Furnace Atmosphere
Atmosphere Heating
Raw materials
Air (oxygen), vacuum inert gas (argon) (oxygen) vacuum, External - electric gas oil electric, gas, Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with iron mix
Furnace material
refractory ceramics
Furnaces
Blast furnace
Basic Oxygen Furnace

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Furnaces
Electric Arc Furnace
Oxygen-Fuel, Oxygen Lance Furnace

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Furnaces
Induction Furnace
Electric Furnace
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Sand Casting g
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Sand Casting
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Sand Casting
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Sand Casting Steps
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20
Sand Cast Parts
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Permanent Mold Casting
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Low Pressure Casting
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Die Casting ( g p g (high pressure) )
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Die Casting Machine
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Die Casting
Cold chamber
Hot chamber
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Direct Squeeze Casting
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Die Casting Part Example
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Continuous Casting
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30
31
32
Investment Casting C ti
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Vacuum Casting
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Investment (top) and Conventional Castings
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Lost Foam Casting
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Lost Foam Castings
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Centrifugal Casting
horizontal
sand-lined mold g casting

vertical
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Centrifugal Casting
39
Pipe Casting Process
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Directional Solidification
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Casting Characteristics
Table 5.6 Typical materials cast
All All
Weig ht (kg)
Process
Sand Shell Expendable E pendable mold pattern
Minimum
0.05 0.05
Maximum
No limit 100+
Typical surface finish (micron, Ra)

5-25 1-3
Section thickness (mm) Shape complexity Dimensional * accuracy*

1-2 2-3 3 2
Porosity*
4 4
Minimum
3 2
Maximum
No limit --
All Nonferrou Plaster s (Al, Mg, mold Zn, Cu) All (High melting Investment pt.) Permanent mold All Nonferrou s (Al Mg (Al, Mg, Die Zn, Cu) Centrifugal All
0.05
No limit
5-20
No limit
0.05
50+
1-2
1-2
--
0.005 0.5
100+ 300
1-3 2-3
3 2-3
1 3-4
1 1
1 2
75 50
<0.05 50 1-2 1-2 3-4 1 -5000+ 2-10 1-2 3-4 3 *Relative rating: 1 best, 5 worst. Note : These ratings are only general; significant variations can occur, depending on the methods used.
0.5 2
12 100
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Microstructure
43
Microstructure - Dendrites
Finer structure at walls Grains / dendrites grow to center

Grains on Willie Bs head Bs
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Microstructure - Dendrites
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Fluidity
47
Casting Defects - Porosity
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Casting Defects
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Shrinkage
TABLE 5.1 Volumetric solidification contraction (%) 6.6 6.3 3.8 2.53 4 4.9 Volumetric solidification contraction (%) 4.5 4 Expansion to 2.5 4.2 45.5 6.5
Metal or alloy Aluminum Al4.5%Cu Al12%Si Carbon steel 1% carbon steel Copper Source: After R. A. Flinn.
Metal or alloy 70%Cu30%Zn 90%Cu10%Al Gray iron g Magnesium White iron Zinc
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Differential Cooling
Transition between thicker and thinner sections can lead to porosity p y
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Pipe Defect
D t shrinkage giving rise t Due to h i k i i i to a funnel-like cavity Solutions
insulate top (glass wool) heat top (exothermic mixture thermit)
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Defects - Hot Tears
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Chills
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Design Rules Summary

Uniform wall thickness Flat parting lines Gradual thickness transitions D ft for removal Draft f l
tapers: 0.5 to 2 degrees
Surface of mold gives surface of part

Sand Casting Rules
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Casting costs
TABLE 5.10 Cost Cost* Process Die Sand L Shell-mold LM Plaster LM Investment MH Permanent mold M Die H Centrifugal M *L l L, low; M medium; H hi h M, di H, high. Equipment L M-H M L-M M H H Labor L M LM LM MH H LM LM LM Production rate (Pc/hr) <20 20 <50 <10 <1000 <60 <200 <50
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Process economics
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Casting Processes Casting Processes: ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009 1

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Casting Processes Casting Processes: ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2009 1

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Casting Processes

Types of Parts Made

Complex, 3-D Complex 3 D shapes

Metals processed by casting

Basic Oxygen Furnace

Electric Arc Furnace

Oxygen-Fuel, Oxygen Lance Furnace

Sand Casting Steps

Sand Cast Parts

Permanent Mold Casting

Low Pressure Casting

Die Casting ( g p g (high pressure) )

Die Casting Machine

Direct Squeeze Casting

Die Casting Part Example

Investment (top) and Conventional Castings

Lost Foam Casting

Lost Foam Castings

sand-lined mold g casting

Pipe Casting Process

Typical surface finish (micron, Ra)

Section thickness (mm) Shape complexity Dimensional * accuracy*

Finer structure at walls Grains / dendrites grow to center

Grains on Willie Bs head Bs

Casting Defects - Porosity

Defects - Hot Tears

Design Rules Summary

Surface of mold gives surface of part

Sand Casting Rules

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