Casting Defects and Process

Casting Processes
ver. 2
ME 4210: Manufacturing Processes and Equipment

Prof. J.S. Colton GIT 2011
Types of Parts Made
Engine blocks
Pipes
Jewelry
Fire hydrants

Complex, 3-D shapes
Near net shape

Low scrap
Relatively quick process
Intricate shapes
Large hollow shapes
No limit to size
Reasonable to good surface finish
Processes
Sand
Shell
Plaster
Ceramic
Investment
Lost foam
Pressure
Vacuum
Die
Centrifugal
Squeeze
Semi-solid
Single crystal
Directional
solidification
Slush
Continuous

Metals processed by casting
Sand casting 60%

Investment casting 7%
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
Continuous casting

Shapes
Permanent mold
(cavity)
die casting
hot chamber
cold chamber
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
Surface finish
die casting 8-16 micro-inches (1-3 mm)
sand casting - 500 micro-inches (10-25 mm)
10
Casting Steps
quick route from raw material to finished
product
Melt metals
Pour / force liquid into hollow cavity
(mold)
Cool / Solidify
Remove
Finish
11
Melting
Raw material (charge)
Furnace
Heat
Atmosphere
scrap, alloying materials
Atmosphere
Raw materials
Air (oxygen), vacuum, inert gas (argon)
Heating
External - electric, gas, oil
Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with iron
Furnace material
refractory ceramics
12
Furnaces
Blast furnace
Basic Oxygen Furnace

13
Furnaces
Electric Arc Furnace
Oxygen-Fuel,
Oxygen Lance Furnace

14
Furnaces
Induction Furnace
Electric Furnace

15
Sand Casting

16
Sand Casting

17
Sand Casting

18
Sand Casting Steps

19

20
Sand Cast Parts

21
Permanent Mold Casting

22
Low Pressure Casting

23
Die Casting (high pressure)

24
Die Casting Machine

25
Die Casting
Cold chamber
Hot chamber

26
Direct Squeeze Casting

27
Die Casting Part Example

28
Continuous Casting

29

30

31

32
Investment
Casting

33
Vacuum Casting

34
Investment (top) and Conventional

Castings

35
Lost Foam Casting

36
Lost Foam Castings

37
Centrifugal Casting
horizontal
sand-lined mold
casting
vertical
38
Centrifugal Casting

39
Pipe Casting
Process

40
Directional Solidification

41
Casting Characteristics
Table 5.6
Typical
Process
Sand
Shell
Expendable
mold
pattern
Plaster
mold
Investment
Permanent
mold
Die
Centrifugal
Weig ht (kg)
Typical
surface
finish
(micron,
Ra)
Section
thickness (mm)
Shape
complexity Dimensional
*
accuracy*
materials
cast
Minimum
Maximum
Minimum
Maximum
All
All
0.05
0.05
No limit
100+
5-25
1-3
4
4
1-2
2-3
3
2
3
2
No limit
--
All
Nonferrou
s
(Al, Mg,
Zn, Cu)
All
(High melting
pt.)
0.05
No limit
5-20
No limit
0.05
50+
1-2
1-2
--
0.005
100+
1-3
75
300
2-3
2-3
3-4
50
0.5
2
12
100
All
Nonferrou
s
(Al, Mg,
Zn, Cu)
All
0.5
Porosity*
<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 use d.

42
Microstructure

43
Microstructure - Dendrites
Finer structure at
walls
Grains / dendrites
grow to center
44
Grains on Willie Bs head

45
Microstructure - Dendrites

46
Fluidity

47
Casting Defects - Porosity

48
Casting Defects

49
Shrinkage
TABLE 5.1
Metal or alloy
Aluminum
Al4.5%Cu
Al12%Si
Carbon steel
1% carbon steel
Copper
Source: After R. A. Flinn.
Volumetric
solidification
contraction (%)
6.6
6.3
3.8
2.53
4
4.9
Metal or alloy
70%Cu30%Zn
90%Cu10%Al
Gray iron
Magnesium
White iron
Zinc

Volumetric
solidification
contraction (%)
4.5
4
Expansion to 2.5
4.2
45.5
6.5
50
Differential Cooling
Transition between thicker and thinner
sections can lead to porosity

51
Pipe Defect
Due to shrinkage giving rise to
a funnel-like cavity
Solutions
insulate top (glass wool)
heat top (exothermic mixture thermit)

52
Defects - Hot Tears

53
Chills

54
Car Rims
Stamped
Cast

55
Casting Defects - Porosity

56
Design Rules Summary

Uniform wall thickness
Flat parting lines
Gradual thickness
transitions
Draft for removal
tapers: 0.5 to 2 degrees
Surface of mold gives

surface of part
57
Sand Casting Rules

58
Casting costs
TABLE 5.10
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
59
Process economics

60

61

Casting Defects and Process

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Casting Processes

ME 4210: Manufacturing Processes and Equipment

Types of Parts Made

ME 4210: Manufacturing Processes and Equipment

Complex, 3-D shapes

Near net shape

ME 4210: Manufacturing Processes and Equipment

Metals processed by casting

Sand casting 60%

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

scrap, alloying materials

Air (oxygen), vacuum, inert gas (argon)

Basic Oxygen Furnace

ME 4210: Manufacturing Processes and Equipment

Electric Arc Furnace

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

Sand Casting Steps

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

Sand Cast Parts

ME 4210: Manufacturing Processes and Equipment

Permanent Mold Casting

ME 4210: Manufacturing Processes and Equipment

Low Pressure Casting

ME 4210: Manufacturing Processes and Equipment

Die Casting (high pressure)

ME 4210: Manufacturing Processes and Equipment

Die Casting Machine

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

Direct Squeeze Casting

ME 4210: Manufacturing Processes and Equipment

Die Casting Part Example

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

Investment (top) and Conventional

ME 4210: Manufacturing Processes and Equipment

Lost Foam Casting

ME 4210: Manufacturing Processes and Equipment

Lost Foam Castings

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

Grains on Willie Bs head

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment

ME 4210: Manufacturing Processes and Equipment