CHAPTER 12

Metal Casting: Design, Materials, and Economics

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Casting Design Modifications

Figure 12.1 Suggested design modifications to avoid defects in castings. Note that sharp corners are avoided to reduce stress concentrations.

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Casting Cross-Sections

Figure 12.2 Examples of designs showing the importance of maintaining uniform cross- sections in castings to avoid hot spots and shrinkage cavities.
Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Avoiding Shrinkage Cavities

Figure 12.3 Examples of design modifications to avoid shrinkage cavities in castings. Source: Steel Castings Handbook, 5th ed. Steel Founders' Society of America, 1980. Used with permission.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Chills
Figure 12.4 The use of metal padding (chills) to increase the rate of cooling in thick regions in a casting to avoid shrinkage cavities. Source: Steel Castings Handbook, 5th ed. Steel Founders' Society of America, 1980. Used with permission.

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Normal Shrinkage Allowance for Some Metals Cast in Sand Molds

TABLE 12.1 Metal Gray cast iron White cast iron Malleable cast iron Aluminum alloys Magnesium alloys Yellow brass Phosphor bronze Aluminum bronze High-manganese steel

Percent 0.831.3 2.1 0.781.0 1.3 1.3 1.31.6 1.01.6 2.1 2.6

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Parting Line
Figure 12.5 Redesign of a casting by making the parting line straight to avoid defects. Source: Steel Casting Handbook, 5th ed. Steel Founders' Society of America, 1980. Used with permission.

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2001 Prentice-Hall

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Casting Design Modifications

Figure 12.6 Examples of casting design modifications. Source: Steel Casting Handbook, 5th ed. Steel Founders' Society of America, 1980. Used with permission.

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2001 Prentice-Hall

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Desirable and Undesirable Die-Casting Practices

Figure 12.7 Examples of undesirable and desirable design practices for die-cast parts. Note that section-thickness uniformity is maintained throughout the part. Source: American Die Casting Institute.

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Mechanical Properties for Various Groups of Cast Alloys

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little ductility and toughness, compared with most other cast alloys, some of which undergo considerable elongation and reduction of area in tension. Note also that even within the same group, the properties of cast alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-10

Mechanical Properties for Various Groups of Cast Alloys (cont.)

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little ductility and toughness, compared with most other cast alloys, some of which undergo considerable elongation and reduction of area in tension. Note also that even within the same group, the properties of cast alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of America.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 12-11

Typical Applications for Casting and Casting Characteristics

TABLE 12.2 Type of alloy Aluminum Copper Ductile iron Gray iron Magnesium Malleable iron Application Pistons, clutch housings, intake manifolds Pumps, valves, gear blanks, marine propellers Crankshafts, heavy-duty gears Engine blocks, gears, brake disks and drums, machine bases Crankcase, transmission housings Farm and construction machinery, heavy-duty bearings, railroad rolling stock Gas turbine blades, pump and valve components for chemical plants Die blocks, heavy-duty gear blanks, aircraft undercarriage members, rail-road wheels Gas turbine housings, pump and valve components, rock crusher jaws Mill liners, shot blasting nozzles, railroad brake shoes, crushers and pulverizers Door handles, radiator grills, Castability* E FG G E GE G Weldability* F F D D G D Machinability* GE FG G G E G

Nickel

Steel (carbon and low alloy) Steel (high alloy)

White iron

VP

VP

Zinc

*E, excellent; G, good; F, fair; VP, very poor; D, difficult.

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Properties and Typical Applications of Cast Irons

TABLE 12.3 Ultimate tensile strength (MPa) 170 275 550 415 550 825 365 450 700 275 Yield strength (MPa) 140 240 550 275 380 620 240 310 550 275 Elongation in 50 mm (%) 0.4 0.4 0 18 6 2 18 10 2 0

Cast iron Gray

Ductile (Nodular)

Malleable

Type Ferritic Pearlitic Martensitic Ferritic Pearlitic Tempered martensite Ferritic Pearlitic Tempered martensite Pearlitic

Typical applications Pipe, sanitary ware Engine blocks, machine tools Wearing surfaces Pipe, general service Crankshafts, highly stressed parts High-strength machine parts,wear-resistant parts Hardware, pipe fittings, general engineering service Railroad equipment, couplings Railroad equipment, gears, connecting rods Wear-resistant parts, mill rolls

White

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Mechanical Properties of Gray Cast Irons

TABLE 12.4 Ultimate tensile strength (MPa) 152 179 214 252 293 362 431 Compressive strength (MPa) 572 669 752 855 965 1130 1293 Elastic modulus (GPa) 66 to 97 79 to 102 90 to 113 100 to 119 110 to 138 130 to 157 141 to 162

ASTM class 20 25 30 35 40 50 60

Hardness (HB) 156 174 210 212 235 262 302

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Properties and Typical Applications of Cast Nonferrous Alloys

TABLE 12.5 Ultimate tensile strength (MPa) 220280 185250 260 235 275 480 260 275 275 230 275 275 160 210 275 Yield strength (MPa) 110220 125180 185 115 95 195 105 105 175 150 95 130 110 105 205 Elongation in 50 mm (%) 8.52 21.5 5 25 25 30 35 30 15 3 12 5 3 8 4

Alloys (UNS) Aluminum alloys 195 (AO1950) 319 (AO3190) 356 (AO3560) Copper alloys Red brass (C83600) Yellow brass (C86400) Manganese bronze (C86100) Leaded tin bronze (C92500) Gun metal (C90500) Nickel silver (C97600) Magnesium alloys AZ91A AZ63A AZ91C EZ33A HK31A QE22A

Condition Heat treated Heat treated Heat treated Annealed Annealed Annealed Annealed Annealed Annealed F T4 T6 T5 T6 T6

Typical applications Sand castings Sand castings Permanent mold castings

Pipe fittings, gears Hardware, ornamental Propeller hubs, blades Gears, bearings, valves Pump parts, fittings Marine parts, valves Die castings Sand and permanent mold castings High strength Elevated temperature Elevated temperature Highest strength

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General Cost Characteristics of Casting Processes

TABLE 12.6 Cost* Process Die Sand L Shell-mold LM Plaster LM Investment MH Permanent mold M Die H Centrifugal M * L, low; M, medium; H, high. Equipment L M-H M L-M M H H Labor LM LM MH H LM LM LM Production rate (Pc/hr) <20 <50 <10 <1000 <60 <200 <50

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