04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

Special molding
Processes
A. Sand moulds
1.
2.
3.
4.
5.
6.
7.
8.

Green sand mould

Dry sand mould
Core sand mould
Carbon dioxide mould (CO2 mould)
Shell mould
Investment mould
Sweep mould
Full mould

B. Metal moulds
9. Gravity die casting or Permanent mould casting
10. Pressure die casting
11. Continuous casting
12. Centrifugal casting
13. Squeeze casting
Hareesha N G, Asst. Prof, DSCE,
14. Thixocasting process
04/29/15
Bengaluru

1. GREEN SAND MOULDS

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

1. GREEN SAND MOULDS

Procedure involved in making green sand moulds
Suitable proportions of silica sand (85 - 92 %), bentonite binder (6-12
%), water (3-5 %) and additives are mixed together to prepare the
green sand mixture.
The pattern is placed on a flat surface with the drag box enclosing it
as shown in figure (a). Parting sand is sprinkled on the pattern surface
to avoid green sand mixture sticking to the pattern.
The drag box is filled with green sand mixture and rammed manually
till its top surface. Refer figure (b). The drag box is now inverted so
that the pattern faces the top as shown in figure (c). Parting sand is
sprinkled over the mould surface of the drag box.
The cope box is placed on top of the drag box and the sprue and riser
pin are placed in suitable locations. The green sand mixture is rammed
to the level of cope box as shown in figure (d).
The sprue and the riser are removed from the mould. The cope box is
lifted and placed aside, and the pattern in the drag box is withdrawn
by knocking it carefully so as to avoid damage to the mould. Gates are
cut using hand tools to provide passage for the flow of molten metal.
Refer figure (e) and (f).
The mould cavity is cleaned and finished. Cores, if any, are placed in
the mould to obtain a hollow cavity in the casting. Refer figure (g).
The cope is now placed on the drag box and both are aligned with the
help of pins. Vent holes are made to allow the free escape of gases
from the mould during pouring. The mould is made ready for pouring.
Refer figure (h).
Hareesha N G, Asst. Prof, DSCE,
04/29/15

Bengaluru

Advantages

Green sand molding is adaptable to machine molding.

No mold baking or drying is required.
There is less mold distortion than in dry sand molding.
Time and cost associated with mold baking or drying is eliminated.
Green sand molds having smaller depths permit the escape of mold gases
without any difficulty.
In green sand molding, flasks are ready for reuse in minimum amount of time.
Being soft, green sand molds do not restrict the free contraction of the
solidifying molten metal.
Green sand molding provides good dimensional accuracy across the parting
line.

Disadvantages
Green sand molds possess lower strengths.
They are less permeable.
There are more chances of defects (like blow holes etc.) occurring in castings
made by green sand molding.
In green sand molding, sand control is more critical than in dry sand molding.
Mold erosion is very common especially in the production of large sized
castings.
Surface finish deteriorates as the weight of the casting increases.
Dimensional accuracy of the castings decreases as their weight increases.
04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

2. DRY MOLDING SAND

Dry molding sand differs from the green molding sand
in the sense that it contains binders (like clay,
bentonite,. molasses etc.) which harden when the
mold is heated and dried.
A typical dry sand mixture (for making non-ferrous
castings) consists of floor sand 40%, new silica sand
30%, coal dust 20% and bentonite 10%.
A dry sand mold is prepared in the same manner as a
green sand mold; however, it is baked at 300 to 700F
for 8 to 48 hours depending upon binders used and
the amount of sand surface to be dried.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

Advantages
Dry sand molds possess high strength.
They are more permeable as compared to green sand molds.
Castings produced from dry sand molds possess clean and smooth
surfaces.
As compared to green sand molding, dry sand molding turns out castings
with less defects.
Dry sand molding imparts better overall dimensional accuracy to the
molds and castings as compared to green sand molding.
Disadvantages
Dry sand molding involves more labour and consumes more time in
completing the mold. Mold baking is an extra work as compared to that
required in green sand molding.
Dry sand molding is more expensive as compared to green sand molding.
Dry sand molding involves chances of hot tears occurring in the castings.
Because of baking, a mold may distort.
Dry sand molding involves a longer processing cycle as compared to
green sand molding.
Dry sand molding gives a slower rate of production as compared to green
sand molding.
04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

4. CARBON DIOXIDE (CO2)

MOLDING
Carbon dioxide moulding also
known as sodium silicate process is
one of the widely used process for
preparing moulds and cores.
In this process, sodium silicate is
used as the binder. But sodium
silicate activates or tend to bind the
sand particles only in the presence
of carbon dioxide gas. For this
reason, the process is commonly
known as C02 process.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

Steps involved in making carbon dioxide mould

Suitable proportions of silica sand and sodium silicate binder (3-5%
based on sand weight) are mixed together to prepare the sand mixture.
Additives like aluminum oxide, molasses etc., are added to impart
favorable properties and to improve collapsibility of the sand.
The pattern is placed on a flat surface with the drag box enclosing it.
Parting sand is sprinkled on the pattern surface to avoid sand mixture
sticking to the pattern.
The drag box is filled with the sand mixture and rammed manually till its
top surface. Rest of the operations like placing sprue and riser pin and
ramming the cope box are similar to that of green sand moulding
process.
Figure (a) shows the assembled cope and drag box with vent holes. At
this stage, the carbon dioxide gas is passed through the vent holes for a
few seconds. Refer figure (b).
Sodium silicate reacts with carbon dioxide gas to form silica gel that
binds the sand particles together. The chemical reaction is given by:
Na2Si03 + C02 -> Na2C03 + Si02
(Sodium Silicate)
(silica gel)
The sprue, riser and the pattern are withdrawn from the mould, and
gates are cut in the usual manner. The mould cavity is finished and
Hareesha N G, Asst. Prof, DSCE,
made
04/29/15ready for pouring. Refer figure (c).
Bengaluru

Advantages
Instantaneous strength development. The development of
strength takes place immediately after carbon dioxide gassing is
completed.
Since the process uses relatively safe carbon dioxide gas, it does
not present sand disposal problems or any odour while mixing
and pouring. Hence, the process is safe to human operators.
Very little gas evolution during pouring of molten metal.

Disadvantages
Poor collapsibility of moulds is a major disadvantage of this
process. Although some additives are used to improve this
property for ferrous metal castings, these additives cannot be
used for non-ferrous applications.
The sand mixture has the tendency to stick to the pattern and
has relatively poor flowability.
There is a significant loss in the strength and hardness of moulds
which have been stored for extended periods of time.
Over gassing and under gassing adversely affects the properties
of cured sand.
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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

10

Fig: 5. SHELL MOULDING steps involved

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

11

5. SHELL MOULDING
Shell moulding is an efficient and
economical method for producing
steel castings.
The process was developed by Herr
Croning in Germany during World
war-II and is sometimes referred to
as the Croning shell process.
Procedure involved in making
shell mould
a. A metallic pattern having the shape
of the desired casting is made in
one half from carbon steel material.
Pouring element is provided in the
pattern itself. Refer figure (a).

b.

The metallic pattern is heated in an oven to a suitable

temperature between 180 - 250C. The pattern is taken out
from the oven and sprayed with a solution of a lubricating
agent viz., silicone oil or spirit to prevent the shell (formed in
later stages) from sticking to the pattern.
c. The pattern is inverted and is placed over a box as shown in
Hareesha
N G, Asst.aProf,
DSCE,
figure 3.3(b). The box
contains
mixture
of dry silica sand or
04/29/15
12
Bengaluru
zircon sand and a resin binder (5% based on sand weight).

d. The box is now inverted so that the

resin-sand mixture falls on the
heated face of the metallic pattern.
The resin-sand mixture gets heated
up, softens and sticks to the
surface of the pattern. Refer figure
(c).
e. After a few seconds, the box is
again inverted to its initial position
so that the lose resin-sand mixture
falls down leaving behind a thin
layer of shell on the pattern face.
Refer figure (d).
f. The pattern along with the shell is
removed from the box and placed
in an oven for a few minutes which
further hardens the shell and
makes it rigid. The shell is then
stripped from the pattern with the
help of ejector pins that are
provided on the pattern. Refer
Hareesha N G, Asst. Prof, DSCE,
figure
04/29/15(e).
Bengaluru

13

g.

Another shell half is prepared

in the similar manner and both
the shells are assembled,
together with the help of bolts,
clips or glues to form a mould.
The assembled part is then
placed in a box with suitable
backing sand to receive the
molten metal. Refer figure (f).
h. After the casting solidifies, it is
removed from the mould,
cleaned and finished to obtain
Advantages
the
desired
shape.
Better
surface
finish and dimensional tolerances.
Reduced machining.
Requires less foundry space.
Semi-skilled operators can handle the process easily.
Shells can be stored for extended periods of time.

Disadvantages
Initially the metallic pattern has to be cast to the desired shape, size
and finish.
Size and weight range
of castings
limited.
Hareesha
N G, Asst. is
Prof,
DSCE,
04/29/15
14
Bengaluru
Process generates noxious fumes.

6. INVESTMENT MOULD

Investment mould also called as 'Precision

casting' or 'Lost wax process' is an ancient
method of casting complex shapes like
impellers, turbine blades and other airplane
parts that are difficult to produce by other
manufacturing techniques.
The various steps involved in this process are:
Step 1 Die and Pattern making
A wax pattern is prepared by injecting liquid
wax into a pre-fabricated die having the same
geometry of the cavity of the desired cast part.
Refer figure.1.
Several such patterns are produced in the
similar manner and then attached to a wax gate
and sprue by means of heated tools or melted
wax to form a 'tree' as shown in figure 2.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

15

Step 2 Pre-coating wax patterns

The tree is coated by dipping into refractory slurry
which is a mixture of finely ground silica flour
suspended in ethyl silicate solution (binder).
The coated tree is sprinkled with silica sand and
allowed to dry. Refer figure 3 and 4.
Step 3 Investment
The pre-coated tree is coated again (referred as
'investment') by dipping in a more viscous slurry
made of refractory flour (fused silica, alumina etc.)
and liquid binders (colloidal silica, sodium silicate
etc.) and dusted with refractory sand.
The process of dipping and dusting is repeated until
a solid shell of desired thickness (about 6 - 10 mm)
is achieved.
Note: The first coating is composed of very
fine particles that produce a good surface
finish, whereas the second coating which is
referred as 'Investment' is coarser so as to
Hareesha
N G, Asst.
Prof, DSCE,
build up the shell of
desired
thickness.
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Bengaluru

16

Step 4 De-waxing
'
The tree is placed in an inverted position and heated in a oven to about
300F. The wax melts and drops down leaving a mould cavity that will
be filled later by the molten metal. Refer figure 5.
Step 5 Reheating the mould
The mould is heated to about 1000 - 2000F (550-1100C) to remove
any residues of wax and at the same time to harden the binder.
Step 6 Melting and Pouring
The mould is placed in a flask supported with a backing material and
the liquid metal of the desired composition is poured under gravity or
by using air pressure depending on the requirement. Refer figure.6.
After the metal cools and solidifies, the investment is broken by using
chisels or hammer and then the casting is cut from the gating
systems, cleaned and finished. Refer figure.7.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

17

Advantages
Gives good surface finish and dimensional tolerances to
castings
Eliminates machining of cast parts.
Wax can be reused.
Disadvantages
Process is expensive.
Size and weight range of castings is limited
In some cases, it is difficult to separate the refractory
(investment) from the casting.
Requires more processing steps.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

18

7. SWEEP MOULD
In sweep moulding, the cavity is formed as the pattern
sweeps the sand all around the circumference.
A thin wooden piece is attached to a spindle at one edge
while the other edge has a contour depending on the
desired shape of the casting.
The spindle is placed at the center of the mould and rotated
so that the wooden piece sweeps in the mould box
generating the shape of the required casting.
Green sand, loam sand or sodium silicate sand can be used
symmetrical shapes.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

19

8. FULL-MOULD PROCESS
Full-mould casting or 'cavity less' casting is a
technique similar to investment casting, but,
instead of wax, polystyrene foam is used as pattern.
The pattern can be hand cut or machined from
pieces of foamed polystyrene.
Gating and risering systems are made from the
foamed material in single or multiple pieces and
then assembled to the pattern with the help of
paste or glue. Refer figure (a).
The entire pattern assembly is dipped into a water
based ceramic material, dried and positioned in a
one piece sand mould.
Green sand or no-bake sand is preferred for
moulding. Refer figure (b).
When the molten metal comes in contact with the
foamed pattern, the foam vaporizes (melts and
burns) allowing the molten metal to occupy and fill
the cavity.
The amount of gas produced by the foam is so small
that it can easily escape through the sand.
Pump housing, manifolds and auto-brake
components are a few among the various products
that can be made from this process.
04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

20

Advantages
Withdrawal of pattern requires some form of design
modifications like providing draft allowance, loose
pieces etc. Such complex processes are eliminated in
full-mould process through the use of patterns that
can be removed by melting and vaporization.
No limit to size and shape of castings.
Good surface finish.
Disadvantages
High cost of patterns.
More care should be taken during moulding.
Patterns being light and low in strength can be easily
distorted or damaged.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

21

Permanent Mold Casting

Steps in permanent mold casting: (1) mold is preheated

and coated
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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

22

Permanent Mold Casting

Steps in permanent mold casting: (2) cores (if used)

are inserted and mold is closed, (3) molten metal is
poured into the mold, where it solidifies.
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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

23

9. GRAVITY DIE CASTING

Gravity die casting or permanent mould casting is a casting

process in which the molten metal is poured into a metallic
mould called die under the influence of gravity. Hence the name
'gravity die casting'.
The mould or die is usually made from cast iron, tool steel,
graphite, copper or aluminum alloys and the choice for a
particular material depends on the type of metal to be cast.
Gating and risering systems are machined either in one or both
the mould halves.
Figure shows a permanent mould made in two halves which
resembles a book. The mould halves are hinged and can be
clamped together to close the mould.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

24

Steps involved in the process

The mould is cleaned using wire brush or compressed air to remove
dust and other particles from it.
It is preheated to a temperature of 200 - 280C by gas or oil flame and
then the surface is sprayed with a lubricant.
The lubricant helps to control the temperature of the die thereby
increasing its life and also assist in easy removal of solidified casting.
The mould is closed tightly and the liquid metal of the desired
composition is poured into the mould under gravity.
After the metal cools and solidifies, the mould is opened and the
casting is removed. Gating and risering systems are separated from
the cast part.
The mould is sprayed with lubricant and closed for next casting. The
mould need not be preheated since the heat in the previous cast is
sufficient to maintain the temperature.
Advantages
Good surface finish and close dimensional tolerances can be achieved.
Suitable for mass production.
Occupies less floor space.
Thin sections can be easily cast.
Eliminates skilled operators.
Disadvantages
Initial cost for manufacturing moulds (dies) is high.
Not suitable for steel and high melting point metals/alloys.
Hareesha N G, Asst. Prof, DSCE,
04/29/15
25
Un-economical
for small productions.
Bengaluru

10. PRESSURE DIE CASTING

Pressure die casting often called 'Die casting' is a casting process
in which the molten metal is injected into a 'die' under high
pressures.
The metal being cast must have a low melting point than the die
material which is usually made from steel and other alloys.
Hence, this process is best suitable for casting non-ferrous
materials, although a few ferrous materials can be cast.
The two basic methods of die casting include:
a) Hot chamber die casting process
b) Cold chamber die casting process.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

26

10.a. Hot chamber die casting process

Figure shows a 'goose neck' type of hot chamber die
casting machine.
In this process, the dies are made in two halves: one half
called the fixed die or 'stationary die while the other half
called 'movable die.
The dies are aligned in positions by means of ejector pins
which also help to eject the solidified casting from the dies.

04/29/15
Figure:

Hareesha N G, Asst. Prof, DSCE,

Hot chamber die
casting
(Submerged plunger type)
Bengaluru

27

Steps involved in the process

A pivoted cast iron goose neck is submerged in a reservoir of molten
metal where the metal enters and fills the goose neck by gravity.
The goose neck is raised with the help of a link and then the neck
part is positioned in the sprue of the fixed part of the die.
Compressed air is then blown from the top which forces the liquid
metal into the die cavity.
When the solidification is about to complete, the supply of
compressed air is stopped and the goose neck is lowered back to
receive the molten metal for the next cycle. In the meantime, the
movable die half opens by means of ejector pins forcing the casting
from the die cavity.
The die halves close to receive the molten metal for the next casting.

Hot chamber process is used for

casting metals like zinc, tin,
magnesium and lead based alloys.
Figure: Hot chamber die casting
Hareesha N G, type)
Asst. Prof, DSCE,
(Goose neck or air injection
04/29/15
Bengaluru

28

10.b: Cold chamber Die Casting Process

In hot chamber process, the charging unit (goose neck) rests in
the melting chamber, whereas in cold chamber process, the
melting chamber is separate and the molten metal is charged into
the machine by means of ladles.
Cold chamber process is employed for casting materials that are
not possible by the hot chamber process.
For example, aluminum alloys react with the steel structure of the
hot chamber machine and as a result there is a considerable iron
pick-up by aluminum.
This does not happen in cold chamber process, as the molten
metal has a momentary contact with the structure of the machine.
Figure
The machine
consists
of a
shows the
cold chamber
die casting machine
die, made in two halves: one
half called the 'fixed die' or
'stationary die while the
other half called 'movable
die.
The dies are aligned in
positions by means of ejector
G, Asst. Prof, DSCE,
04/29/15
29
pins which also help toHareesha
ejectNBengaluru
Fig: cold chamber die casting machine

Steps involved in the process

A cylindrical shaped chamber called 'cold chamber' (so

called because, it is not a part of melting or charging unit
unlike in hot chamber process) is fitted with a freely moving
piston and is operated by means of hydraulic pressure.
A measured quantity of molten metal is poured into the
cold chamber by means of ladles.
The plunger of the piston is activated and progresses
rapidly forcing the molten metal into the die cavity. The
pressure is maintained during the solidification process.
After the metal cools and solidifies, the plunger moves
backward and the movable die half opens by means of
ejector pins forcing the casting from the die cavity.
The cold chamber process is slightly slower when compared
to the hot chamber process.

04/29/15

Hareesha N G, Asst. Prof, DSCE,

Bengaluru

30

Advantages of Die casting process

Process is economical for large production quantities.
Good dimensional accuracy and surface finish.
Thin sections can be easily cast.
Near net shape can be achieved.
Disadvantages
High cost of dies and equipment.
Not economical for small production quantities.
Process not preferable for ferrous metals.
Part geometry must allow easy removal from die cavity

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

31

11. CONTINUOUS CASTING

Continuous casting is a casting process in which the operation of
pouring, solidification and withdrawal of casting from an open
mould are carried out continuously.
Figure shows a schematic of the process.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

32

Steps involved in the process

1. The molten metal is continuously supplied from the ladle to the
intermediate ladle called 'tundish' from where it is continuously poured
into the mould at a controllable rate, keeping the level at a constant
position.
2. The mould usually made of copper or graphite is open at the bottom
and is water cooled so as to extract the heat of the metal causing its
solidification. The shape of the mould corresponds to the shape of the
desired casting.
3. The process is started by placing a dummy bar at the bottom of the
mould upon which the first liquid metal falls.
4. The molten metal from the tundish enters the mould and takes the
shape of the mould. The water cooled mould controls the cooling rate
of the metal, so that it solidifies before it leaves the mould.
5. The metal after coming out of the mould is further cooled by direct
water spray (or water with air) to complete solidification.
6. The solidified metal is continuously extracted (along with the dummy
bar) by 'pinch rolls', bent and fed horizontally and finally cut to the
desired length.
7. The dummy bar is initially placed at the bottom of the mould to receive
the first liquid metal (since the bottom of the mould is open). It is later
Hareesha N G, Asst. Prof, DSCE,
disconnected
from the casting.
04/29/15
33
Bengaluru

Advantages
Sprue, runner, riser etc., are not used. Hence, no
waste metal. This leads to 100 % casting yield*.
Capable of producing in single operation, rods,
sections and tubes with varying sizes and wall
thickness.
Process is automatic.
Product has good consistent soundness.
Mechanical properties are high
Disadvantages
Not suitable for small quantity production.
Continuous and efficient cooling of moulds is required,
else, center-line shrinkage develops.
Requires large floor space.

* Yield - Comparison of casting weight

to the total weight of the metal
poured into the mould.
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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

34

12. CENTRIFUGAL CASTING

Centrifugal casting is a process in which the molten metal
is poured and allowed to solidify in a revolving mould.
The centrifugal force due to the revolving mould holds the
molten metal against the mould wall until it solidifies.
The material used for preparing moulds may be cast iron,
steel, sand or graphite (for non-ferrous castings).
The process is used for making castings of hollow
cylindrical shapes.
The various centrifugal casting techniques include:
a)
b)
c)

True centrifugal casting

Semi-centrifugal casting and
Centrifuge casting.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

35

12.a. True Centrifugal casting

True centrifugal casting is used to produce parts that are
symmetrical about the axis like that of pipes, tubes,
bushings, liners and rings.
The outside shape of the casting can be round, octagonal,
hexagonal etc., but the inside shape is perfectly
(theoretically) round due to radially symmetric forces.
This eliminates the need for cores for producing hollow
castings.
Figure shows the true centrifugal process.

04/29/15

Hareesha N G,Figure:
Asst. Prof, DSCE,
True
Bengaluru

centrifugal process
36

Steps involved in the process

1.
2.
3.
4.
5.

The mould of the desired shape is prepared with metal and the walls are coated with a
refractory ceramic coating.
The mould is rotated about its axis at high speeds in the range of 300 - 3000 rpm. A measured
quantity of molten metal is poured into the rotating mould.
The centrifugal force of the rotating mould throws the liquid metal towards the mould wall and
holds the molten metal until it solidifies.
The casting cools and solidifies from its outer surface towards the axis of rotation of the mould
thereby promoting directional solidification.
The thickness of the casting obtained can be controlled by the amount of liquid metal being
poured.

An inherent quality of true centrifugal castings is based on the fact that, the non-metallic
impurities in castings being less dense than the metal, are forced towards the inner
surface (towards the axis) of the casting due to the centrifugal forces. These impurities
can be machined later by a suitable machining process (say boring operation).
The mould may be rotated horizontally or vertically.
When the mould is rotated about horizontal axis, a true cylindrical inside surface is
produced; if rotated on a vertical axis, parabolic inside surface is produced.
Cores and gating/risering systems are not required for this process.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

37

12.b. Semi-centrifugal casting

Semi-centrifugal casting process is used to produce solid castings
and hence, requires a core to produce hollow cavities.
The process is used only for symmetrically shaped objects and the
axis of rotation of the mould is always vertical.
Gear blanks, sheaves, wheels and pulley are the commonly
produced parts by this process.
Figure shows the process to produce a wheel shaped casting.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

38

Steps involved in the process

The mould is prepared in the usual manner using cope and drag
box.
The mould cavity is prepared with its central axis being vertical
and concentric with the axis of rotation.
The core is placed in position and the mould is rotated at suitable
speeds, usually less than true centrifugal casting process.
The centrifugal force produced due to the rotation of the mould
causes the molten metal to fill the cavity to produce the desired
shape.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

39

12.c. Centrifuging Process

In true and semi centrifugal process, the axis of the
mould/cavity coincide with the axis of rotation.
Where as in centrifuging process, the axis of the mould
cavity does not coincide with the axis of rotation.
The mould is designed with part cavities located away from
the axis of rotation.
Hence, this process is suitable for non-symmetrical
castings.
Figure shows the centrifuging process.

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Bengaluru

40

Steps involved in the process

1. Several mould cavities are arranged
in a circle and connected to a central
down sprue through gates.
2. The axis of the down sprue is common
to the axis of rotation of the mould.
3. As the mould is rotated, the liquid
metal is poured down the sprue which
feeds the metal into the mould cavity
under centrifugal force.
4. The rotational speed depends on a
number of factors such as, the
moulding medium (sand, metal or
ceramic), size of the casting, type of
metal being poured and the distance
of the cavity from the central axis
(sprue axis).
5. Centrifuging is done only about a
vertical axis.
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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

41

13. SQUEEZE CASTING

Squeeze casting or squeeze forming or liquid metal forging is a
combination of casting and forging process.
Figure shows the sequence of operations involved in the process.

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Bengaluru

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Steps involved in the

process
1. The process makes use of two
dies: bottom die and top die, cast
and machined in such a way that
upon mating leaves a cavity
similar to the shape of the desired
casting. Refer figure (a).

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2. The bottom die is preheated to

around 200 - 250C with the help
of a torch and sprayed by a water
based graphite lubricant to
facilitate easy removal of casting
after solidification. Refer figure
Hareesha N G, Asst. Prof, DSCE,
43
(b).
Bengaluru

3. Measured quantity of molten metal is poured into the

bottom die as shown in figure (c). As the metal starts
solidifying, pressure is applied to the top die causing it to
move rapidly towards the bottom die.
4.This causes the molten metal to get squeezed and fill the
mould cavity. Refer figure (d). The squeezing pressure is
applied until solidification is completed.
5.The casting is ejected by operating the lift pin provided in
the bottom die, and the die is then made ready for the next
cycle. Refer figure (e)
Squeeze casting is commonly used for casting aluminum and
magnesium alloys.
Cores can be used in this process to produce holes and recesses.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

44

Advantages
Metals which have poor fluidity characteristics can be
cast by this process.
Shrinkage and gas porosity will be less due to the
applied pressure during solidification.
Enhanced mechanical properties because of the fine
grain structure caused by rapid solidification.
Good surface finish.
Disadvantages
Process is costlier. Manufacturing of dies to accurate
dimensions involves complex processes.
Accurate metering of molten metal is a slight difficult
problem.
Un-economical for small quantity production.

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

45

14. SLUSH CASTING

Slush casting is a process in which hollow castings are produced
without the use of cores.
The process is not preferred to produce objects for engineering
use, instead, it is used to make objects like statues, toys, lamp
base, candle sticks and others, where only the external features
of the object are important. Refer figure (c).

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Hareesha N G, Asst. Prof, DSCE,

Bengaluru

46

Steps involved in the process

In this process, the molten metal is poured in a metallic mould and
permitted to remain in the mould for a short interval of time. Refer
figure (a).
Solidification begins at the mould walls, as they are relatively cool and
then progresses inward.
When a shell of desired thickness is formed, the mould is inverted and
the metal which is still in the liquid state is drained off. Refer figure (b).
The thickness of the shell obtained depends on the time for which the
metal was allowed to remain in the mould and also the thermal
conductivity of the mould.
When the mould halves are separated, a hollow casting with good
features on its external surfaces, but variable wall thickness is,
obtained as shown in figure (c).
Advantages
Process is inexpensive.
Hollow castings can be made without using cores.
Disadvantages
Process is used for art and decorative work only.
Only low melting point alloys with narrow freezing ranges can be used.
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Bengaluru

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15. THIXOCASTING PROCESS

Thixocasting, although similar to squeeze
casting, is a more refined process in which the
casting material, for example, aluminum alloy
is subjected to a heating treatment to prepare
a semi-molten material having solid and liquid
phases co-existing therein.
The semi-molten material is injected into a
cavity whose shape resembles to the shape of
the desired product and rapidly compressed at
very high pressures.
This is a high potential technology bringing
together quality metallurgy, advanced
mechanical properties and excellent
dimensional precision.
The yield strength of the part made by
thixocasting is around 220 MPa compared to a
maximum of 140 MPa, that obtained by a
pressure die casting process.
It is therefore used in the manufacture of light
weight parts especially in automobiles that
Hareesha N G, Asst. Prof, DSCE,
are
subjected to severe stresses.
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48