Casting Processes and

Engineering
1.Casting Technology
Introduction, Casting Process, safety, Major casting methods
Dr J Bhaskaran

Dr. J Bhaskaran, Astu

ntroduction
Metal casting process begins by creating a mould, which is the
'reverse' shape of the part we need
The mould is made from a refractory material, for example, sand.
The metal is heated in an oven until it melts, and the molten metal
is poured into the mould cavity.
The liquid takes the shape of cavity, which is the shape of the part.
It is cooled until it solidifies. Finally, the solidified metal part is
removed from the mould.

Dr. J Bhaskaran, Astu

Reason for casting
Casting can produce very complex geometry parts with internal
cavities and hollow sections.
It can be used to make small (few hundred grams) to very large
size parts (thousands of kilograms)
It is economical, with very little wastage: the extra metal in each
casting is re-melted and reused
Cast metal is isotropic - it has the same physical/mechanical
properties along any direction.

Dr. J Bhaskaran, Astu

Sand casting Process

Dr. J Bhaskaran, Astu

Preparation of Mould and casting the
component

 Sand casting is one of the older

techniques.
 In this form a mould is made from sand,
and the part is cast into it.
 When the metal has hardened and
cooled the part is removed, and the
sand removed.

Dr. J Bhaskaran, Astu

Sand Casting Process (Pictorial view)

Dr. J Bhaskaran, Astu

Hierarchical classification of various casting
processes

Classification continued in
next slide
Dr. J Bhaskaran, Astu
Hierarchical classification of various casting
processes (cont…..)

Dr. J Bhaskaran, Astu

Major Casting Processes
Today, there are a large number of industrial casting processes (see Fig in previous slide). These
can be classified based on the mould material, method of producing the mould and the pressure
on molten metal during filling (gravity, centrifugal force, vacuum, low pressure, high pressure).
Permanent or metal moulds are used in gravity and pressure die casting processes, suitable for
producing a large number of components.
In expendable mould processes (sand, shell and investment), a new mould is required for every
casting or a bunch of castings with a common gating and feeding system produced in the same
mould.
Expendable moulds can be made using either permanent pattern or expendable pattern.
Permanent pattern can be made from wood, metal or plastic.
In expendable pattern processes (also called investment processes), each pattern produces only
one casting. Such patterns are made of wax, expandable polystyrene (EPS) or other polymer
materials.
The four most popular processes are briefly described below, followed by a comparison of their
capabilities (Table 1.3). The first two employ dispensable moulds, whereas the last two employ
permanent moulds.

Dr. J Bhaskaran, Astu

Permanent mould casting

Dr. J Bhaskaran, Astu 1

Simplified flow diagram
of basic operation
Figure shows a simplified flow
diagram of the basic
operations for producing a
sand casting.
There are variations from this
flow sheet depending on the
type of material cast, the
complexity of the component
shape, and the quality
requirements established by
the customer.
 There are also many
alternative methods of
accomplishing each of these
tasks.

Dr. J Bhaskaran, Astu 1

Permanent mould casting (cont….)
Here, the two halves of the mould are made of metal, usually cast
iron, steel, or refractory alloys.
The cavity, including the runners and gating system are machined
into the mould halves. For hollow parts, either permanent cores
(made of metal) or sand-bonded ones may be used, depending on
whether the core can be extracted from the part without damage
after casting.
The surface of the mould is coated with clay or other hard refractory
material – this improves the life of the mould. Before moulding, the
surface is covered with a spray of graphite or silica, which acts as a
lubricant.
This has two purposes - it improves the flow of the liquid metal, and
it allows the cast part to be withdrawn from the mould more easily.

Dr. J Bhaskaran, Astu 1

 Specialised Casting Classification
Die casting
High-pressure die casting
Low-pressure die casting
Gravity die casting (permanent mould)
Centrifugal casting
Vertical centrifugal casting
Horizontal centrifugal casting
Hybrid processes
Squeeze casting
Semisolid metal casting (rheocasting)
Osprey process

Dr. J Bhaskaran, Astu 1

Expandable mould

(a) Wax patterns are produced by injection moulding

Example : Investment casting [It can also be

referred to Expandable pattern]

In expendable mould processes (sand, shell and

investment), a new mould is required for every casting or
a bunch of castings with a common gating and feeding
system produced in the same mould.

(b) Multiple patterns are assembled to a central wax sprue

Dr. J Bhaskaran, Astu 1

Expandable mould (cont…)

(c) A shell is built by immersing the assembly in a liquid

ceramic slurry and then into a bed of extremely fine sand.
Several layers may be required.

(d) The ceramic is dried; the wax is melted out; ceramic

is fired
to burn all wax

Dr. J Bhaskaran, Astu 1

Expandable mould (cont….)
(e) The shell is filled with molten metal by
gravity pouring. On solidification, the
parts, gates, sprue and pouring cup
become one solid casting. Hollow casting
can be made by pouring out excess metal
before it solidifies
(f) After metal solidifies,
the ceramic shell is broken
off by vibration or water
blasting
Dr. J Bhaskaran, Astu
(g) The parts are cut away from
the sprue using a high speed
friction saw. Minor finishing
gives final part.
1
 Expandable pattern casting(lost foam
process)
• The pattern used in this process is made from polystyrene
(this is the light, white packaging material which is used to
pack electronics inside the boxes). Polystyrene foam is 95% air
bubbles, and the material itself evaporates when the liquid
metal is poured on it.
• The pattern itself is made by moulding - the polystyrene beads
and pentane are put inside an aluminium mould, and heated;
it expands to fill the mould, and takes the shape of the cavity.
• The pattern is removed, and used for the casting process, as
follows

Dr. J Bhaskaran, Astu 1

 Expandable pattern casting(lost foam
process) [cont…..]
The pattern is dipped in a slurry of water and clay (or
other refractory grains); it is dried to get a hard shell
around the pattern.
The shell-covered pattern is placed in a container with
sand for support, and liquid metal is poured from a
hole on top.
The foam evaporates as the metal fills the shell; upon
cooling and solidification, the part is removed by Molten metal
breaking the shell.
Polystyren
The process is useful since it is very cheap, and yields e burns;
good surface finish and complex geometry. There are gas
no runners, risers, gating or parting lines - thus the
design process is simplified. escapes
The process is used to manufacture crank-shafts for
engines, aluminium engine blocks, manifolds etc.

Dr. J Bhaskaran, Astu 1

Safety in foundry shop
In all kinds of industries, each shop supervisor is generally
assigned the responsibility of safety in his shop regarding
the men, machines and materials. Every supervisor in each
shop ensures to the top executives in respect of all kinds of
the safety matters. He is supposed to incorporate all new
safety measures needed in the shop from time to time
A thorough discussion of the safety precautions involved in
foundry melting is highly recommended for any and all melt
room activities. The three areas of metal melting that
require special attention (furnace operation, furnace
design, and personnel protection) are discussed

Dr. J Bhaskaran, Astu 1

(i)Furnace Operation
Most accidents occur during the charging and removal of molten
metal. Worker exposure to splashes and potential explosions should
be examined closely. Training programs are often required so that
operators have a good understanding of all necessary precautions
and safety measures. Such measures include the following
Whenever possible, carefully preheated charges should be used.
This will avoid the possibility of loading water or moisture-
containing charges
All areas around a melting furnace should be clear of obstructions
to provide quick evacuation or escape routes in case of emergency
Clean, dry, and carefully coated ladles and other tools should be
used at all times

Dr. J Bhaskaran, Astu 2

(i)Furnace Operation [Cont….]
Thorough preheating procedures should be followed before
any tool is used in the bath
Safety equipment and instructions for its use should be
prominently displayed in case of furnace leaks or failures
A well-conceived plan should be implemented to minimize
potential hazards and to prepare personnel for any
emergency
Few of the materials used in most foundry hearth furnace
operations can be considered hazardous. National Institute of
Occupational Safety and Health programs require that
Material Safety Data Sheets be readily available and used
Dr. J Bhaskaran, Astu 2
(ii) Furnace Design
A principal consideration in furnace design should be to minimize
worker exposure to splashing or exploding metal. Most furnace
designers avoid floor-level charging wells as a concession to this
safety consideration; instead, they use dip-out and charge wells
that are waist high or higher. This enables the operator to avoid
most splashes and spills of molten metal.
In the past, the furnace-tapping operation was a high-risk activity.
Today, however, with the availability of insulated fibre cones or
plugs, much of the problem has been overcome. Protective
clothing should be worn, and at least two well protected operators
should be on hand when a furnace is being tapped. When an
oxygen lance is used to open a tap hole, extreme care and full
protective clothing and head gear should be used.

Dr. J Bhaskaran, Astu 2

 (iii) Personnel Protective Equipment and
Clothing
Protection from flying molten metal due to splashes and minor
explosions is the key to the selection of proper clothing and
safety equipment.
The use of wool shirts and trousers is a long-standing solution
to these hazards. A metal splash causes the apparel to emit the
odour of burning wool, and quickly warns the wearer of a
potential problem.
Clothes made of acrylic and other synthetic fibres should never
be worn in the melting area, because they easily burn or form a
hot liquid that can produce very serious burns. A 0.5 kg (1 lb)
quantity of aluminium at 675 °C (1250 °F) that is plunged
directly into water will produce an explosion equivalent to 1.4
kg (3 lb) of TNT.

Dr. J Bhaskaran, Astu 2

A regular preventive maintenance program
It should include operation and condition checks on the following items:
Burner block and refractory conditions
Burner systems. Particular attention should be paid to deposits on and in
the burners
Fuel-to-air ratios. Unless constant-temperature air is used for combustion,
fuel-to-air ratios should be checked carefully. With any major difference in
air temperature (for example, seasonal changes), air volume must be
adjusted to supply the proper amount of oxygen for efficient fuel use and
melting
Tap hole condition (inside and out)
Flue or stack condition, particularly at the exit from the furnace chamber
Housekeeping in the working and safety lane areas

Dr. J Bhaskaran, Astu 2

Thank you

Dr. J Bhaskaran, Astu 2