2.

3 Casting Processes
Casting process can be defined as a manufacturing process involves pouring of liquid metal into a mould cavity and then allowing it to solidify. The final shape of the metal was determined by the shape of the mould cavity. The solidified metal is also refers as a casting. The casting processes can be broadly classified by the type of mould used as illustrate in figure 8. The expandable mould is non reusable mould and usually destroyed to remove out the solidified cast. In contrast, the permanent can be reuse to make other casting.

Figure 8: Classifications of Casting Processes

In a basic casting process, the mould must be produce based on the desired shape. Followed by melting process where metal is heated in furnace until it changed into liquid form the molten metal is poured into mould cavity. Lastly, when the solidification process is finished, the mould is broke or opened to take out the product. The basic step for casting process presented as per below: Mould Cavity: A mould cavity must have the desired shape and size. It also must have a refractory character so that it will not be significantly affected by the molten metal that it must contain. There are two major types of mould which is expendable mould and non-expendable mould. The expendable mould only used for single process and new mould must be prepared for next casting. For the non-expendable mould usually made from strong material that withstand for using in repeated casting process. Melting Process: A melting process must be capable of providing molten material not only at the proper temperature, but also in the desired quantity, with an acceptable quality, and within a reasonable cost.[3]

Pouring Techniques: Before pouring process, provision should be made to permit the escape of all air or gases in the mould. The hot metal is poured into mould and then completely filled the cavity in fully dense and no defect. Solidification Process: Provision must be made so that the mould will not cause too much restraint to the shrinkage that accompanies the cooling of solidified metal. Otherwise, the casting will crack when it is still hot and its strength is low.[3] Mould Removal: Remove the casting from the mould is done after the solidification process finished. Usually the difficulty occurs while removal of the casting for permanent mould. Cleaning, Finishing and Inspection: Extraneous material that is attached where the metal entered the cavity, excesses at mould parting lines, and mould material that is attached to the casting surface must all be removed.