VEER SURENDRA SAI UNIVERSITY OF

TECHNOLOGY, BURLa

Project report
On
“CAVITYLESS CASTING/EVAPORATIVE
CASTING”
Submitted by
Uttam mahato - 15010778
Jyotiranjan sena - 15020156
Sujata kindo - 1603090036
Guided by
Superintendent of workshop
Dr.Rabindra behera
Submitted to
Veer Surendra Sai University of Technology, Burla
For academic year
2019-2020
Sl no. Contents page no
1 Introduction
2
3
4
5
6
7
INTRODUCTION
 1-CASTING
Casting is a manufacturing process in which a liquid material is usually poured
into a mould, which contains a hollow cavity of the desired shape, and then
allowed to solidify. The solidified part is also known as a casting, which is ejected
or broken out of the mould to complete the process. Casting materials are
usually metals or various time setting materials that cure after mixing two or
more components together; examples are epoxy, concrete, plaster and clay.
Casting is most often used for making complex shapes that would be otherwise
difficult or uneconomical to make by other methods. Heavy equipment like
machine tool beds, ships' propellers, etc. can be cast easily in the required size,
rather than fabricating by joining several small pieces.

Different Types of Casting and the Casting Process

Although casting is one of the oldest known manufacturing techniques, modern
advances in casting technology have led to a broad array of specialized casting
methods. Hot forming processes, such as die casting, investment casting, plaster
casting, and sand casting, each provide their own unique fabrication benefits.
Comparing both the advantages and disadvantages of the common types of
casting processes can help in selecting the method best-suited for a given
production run.

Comparative Advantages, Disadvantages and Applications for

Various Casting Methods:

Advantages
Least Expensive in small
quantities (less than 100)
Ferrous and non - ferrous
metals may be cast
Possible to cast very large
parts.
• Least expensive
tooling
Permanent and Semi-permanent Mold Casting
Sand Casting
Disadvantages Recommended Application
Dimensional accuracy Use when strength/weight
inferior to other processes, ratio permits
requires larger tolerances
Tolerances, surface finish
Castings usually exceed and low machining cost does
calculated weight not warrant a more
expensive process
Surface finish of ferrous
castings usually exceeds 125
RMS
Less expensive than Only non-ferrous metals may Use when process
Investment or Die Castings be cast by this process recommended for parts
subjected to hydrostatic
Dimensional Tolerances Less competitive with Sand pressure
closer than Sand Castings Cast process when three or
more sand cores are required Ideal for parts having low
Castings are dense and profile, no cores and
pressure tight Higher tooling cost than quantities in excess of 300
Sand Cast
Plaster Cast
Smooth "As Cast" finish (25 More costly than Sand or Use when parts require
RMS) Permanent Mold-Casting smooth "As Cast" surface
finish and closer tolerances
Closer dimensional tolerance Limited number of sources than possible with Sand or
than Sand Cast Permanent Mold Processes
Requires minimum of 1 deg.
• Intricate shapes and draft
fine details including thinner
"As Cast" walls are possible

• Large parts cost less

to cast than by Investment
process
Investment Cast
Close dimensional tolerance Costs are higher than Sand, Use when Complexity
Permanent Mold or Plaster precludes use of Sand or
Complex shape, fine detail, process Castings Permanent Mold Castings
intricate core sections and
thin walls are possible The process cost is justified
through savings in
Ferrous and non-ferrous machining or brazing
metals may be cast
Weight savings justifies
As-Cast" finish (64 - 125 increased cost
RMS)
Die Casting
Good dimensional tolerances Economical only in very Use when quantity of parts
are possible large quantities due to high justifies the high tooling cost
tool cost
Excellent part-part Parts are not structural and
dimensional consistency Not recommended for are subjected to hydrostatic
hydrostatic pressure pressure
Parts require a minimal post applications
machining
For Castings where penetrant
(die) or radiographic
inspection are not required.
Difficult to guarantee
minimum mechanical
properties
 2-CAVTYLESS CASTING/ FULL
MOULDING/EVAPORATIVE PATTERN
CASTING
1. To produce complex shape of the objects in mass production, this
technique is used.
2. Pattern is produced by plastic material and number of gating elements
will be added on the pattern.
3. Slurry coatings are provided on the pattern and refractory materials will
be added to produce a shell around the pattern.
4. By providing pattern and shell inside the mould box, sand will be filled
and by providing vibrating mechanism, moulding sand will be settled
inside the mould box.
5. Liquid metal is directly allowed on the pattern. Due to high temperature,
pattern will start evaporation and it will be converted into gaseous form.
6. By allowing the gases to escape, cavity can be created into which liquid
metal will be simultaneously filled and it allowed to solidify.
7. After solidification, by breaking the mould the required casting can be
produced.
8. If moulding material is replaced by plaster of Paris then it is called
plaster moulding. It is used to produce low melting point non-ferrous
materials.

Applications
1. Tooling’s
2. Fittings
3. Lock components
4. Motor casting, etc..
Evaporative-pattern casting
Evaporative-pattern casting is a type of casting process that uses a pattern
made from a material that will evaporate when the molten metal is poured
into the moulding cavity. The most common evaporative-pattern material used
is polystyrene foam.

The two major evaporative-pattern casting processes are:

 Lost-foam casting
 Full-mould casting

Lost-foam casting (LFC) is a type of evaporative-pattern casting process that

is similar to investment casting except foam is used for the pattern instead
of wax. This process takes advantage of the low boiling point of polymer
foams to simplify the investment casting process by removing the need to
melt the wax out of the mould.

Advantages and disadvantages

 Lost foam is generally more economical than investment casting
because it involves fewer steps.
 Risers are not usually required due to the nature of the process.
 The flexibility of LFC often allows for consolidating the parts into
integral component; other forming processes would require the
production of one or more parts to be assembled.
 Disadvantages are that pattern costs can be high for low volume
applications and the patterns are easily damaged or distorted due
to their low strength.
Full-mould casting is an evaporative-pattern casting process which is a
combination of sandcasting and lost-foam casting. It uses an expanded
polystyrene foam pattern which is then surrounded by sand, much like sand
casting. The metal is then poured directly into the mould, which vaporizes the
foam upon contact.
Full-mould casting
1. Molten metal
2. Coated pattern
3. Foam
4. Green sand
5. Flask

Advantages and disadvantages

 As compared to investment casting, it is cheaper because it is a simpler

process and the foam is cheaper than the wax.
 Risers are not usually required due to the nature of the process;
because the molten metal vaporizes the foam the first metal into the
mould cools more quickly than the rest, which results in natural
directional solidification.
 Disadvantages are that pattern costs can be high for low volume
applications and the patterns are easily damaged or distorted due to
their low strength. If a die is used to create the patterns there is a large
initial cost.
 3-ALLOY OF ALUMINIUM
An aluminium alloy is a composition consisting mainly of aluminium to which
other elements have been added. The alloy is made by mixing together the
elements when aluminium is molten (liquid), which cools to form a
homogeneous solid solution. The other elements may make up as much as 15
percent of the alloy by mass. Added elements include iron, copper,
magnesium, silicon, and zinc. The addition of elements to the aluminium gives
the alloy improved strength, workability, corrosion resistance, electrical
conductivity, and/or density, compared with the pure metallic element.
Aluminium alloys tend to be lightweight and corrosion resistant.

List of Aluminum Alloys

This is a list of some important aluminum or aluminium alloys.

 AA-8000: used for building wire per the National Electrical Code
 Alclad: aluminum sheet made by bonding high-purity aluminum to a high
strength core material
 Al-Li (lithium, sometimes mercury)
 Alnico (aluminum, nickel, copper)
 Birmabright (aluminum, magnesium)
 Duralumin (copper, aluminum)
 Hindalium (aluminum, magnesium, manganese, silicon)
 Magnalium (5% magnesium)
 Magnox (magnesium oxide, aluminum)
 Nambe (aluminum plus seven other unspecified metals)
 Silumin (aluminum, silicon)
 Titanal (aluminum, zinc, magnesium, copper, zirconium)
 Zamak (zinc, aluminum, magnesium, copper)
 Aluminum forms other complex alloys with magnesium, manganese, and
platinum.

The Strongest Aluminum Alloy

Manganese added to aluminum increases its strength and yields an alloy with
excellent workability and corrosion resistance. The highest strength alloy in the
non-heat-treatable grade is alloy 5052.
Aluminum Alloy Classification
In general, the two broad categories of aluminum alloys are wrought alloys and
casting alloys. Both of these groups are subdivided into heat-treatable and
non-heat-treatable types. Around 85% of aluminum is used in wrought alloys.
Cast alloys are relatively inexpensive to produce because of their low melting
point, but they tend to have lower tensile strengths than their wrought
counterparts.

Applications.
Aluminium alloys are economical in many applications.
They are used in the automotive industry, aerospace industry, in construction
of machines, appliances, and structures, as cooking utensils, as covers
for housings for electronic equipment, as pressure vessels for
Cryogenic applications, and in innumerable other areas.
 4-RISER DESIGN
Riser is defined as a reservoir for supplying molten metal to the casting cavity
to compensate (additional molten metal) the liquid shrinkages taking place due
to solidification.
The riser is a reservoir in the mould that serves as a source of liquid metal for
the casting to compensate for shrinkage during solidification. The riser must be
designed to freeze after the main casting in order to satisfy its function Riser
Function As described earlier, a riser is used in a sand-casting mould to feed
liquid metal to the casting during freezing in order to compensate for
solidification shrinkage.
To function, the riser must remain molten until after the casting solidifies.
The riser represents waste metal that will be separated from the cast part and
re-melted to make subsequent castings. It is desirable for the volume of metal
in the riser to be a minimum. Risers can be designed in different forms.
Risers can be open or blind. An open riser is exposed to the outside at the top
surface of the cope. This has the disadvantage of allowing more heat to
escape, promoting faster solidification. A blind riser is entirely enclosed within
the mould.
Riser Location
To determine the correct riser location, the methods engineer must make use
of the concept of directional solidification. If shrinkage cavities in the casting
are to be avoided, solidification should proceed directionally from those parts
of the casting farthest from the riser, through the intermediate portions of the
casting, and finally into the riser itself, where the final solidification will occur.
Shrinkage at each step of solidification is thus fed by liquid feed metal being
drawn out of the riser.

The ability to achieve such directional solidification will depend on:

• · The alloy and its mode of solidification

• · The mould medium

• · The casting design

METHODS OF RISER DESIGN

1. Caine’s method
2. Modulus method
3. NRL method (Naval Research Method)

MODULUS METHOD
The modulus method is the inverse of cooling characteristic (surface
area/volume) and is defined as earlier.
𝑣𝑜𝑙𝑢𝑚𝑒
Modulus =
𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎

𝜋𝐷²
Volume =
4

Where, D= diameter of the riser

The bottom end of the riser is in contact with the casting and thus
does not contribute to the calculation of surface area.
𝜋𝐷²
Surface area = + 𝜋𝐷²
4
The modulus of such a cylinder riser, Mᵣ would be
Mᵣ = 0.2 D
Since Mᵣ = 1.2 𝑀𝑐
D = 6 𝑀𝑐
Where,
𝑀𝑐 = modulus of casting
 5-NUMERICAL

DESIGN OF RISER
Modulus method
𝑀𝑐 = 0.8 - 1.2 𝑀𝑟
𝑣𝑜𝑙𝑢𝑚𝑒
Modulus =
𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎

For section- I
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐼
𝑀𝑜𝑑𝑐 =
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝐼

Vol. = 5×10×1
= 50 cm³
C.S.A = 2(10×1) + (5×1) + (10×5)
= 20 + 5 + 100
=125 cm²
50
𝑀𝑜𝑑𝑐 =
125
= 0.4
For section- II
Volume II = 10 × 2 × 5
= 100 cm³
C.S.A = 2(10×2) + 2(5×10) + (5×1)
= 40 + 100 + 5
= 145 cm²
100
𝑀𝑜𝑑𝑐 =
145

= 0.689
For section- III
Volume III = 10 × 3 × 5
= 150 cm³
C.S.A = 2(10×3) + 2(5×10) + (5×1) + (3×5)
= 60 + 100 + 5 + 15
= 180 cm²
150
𝑀𝑜𝑑𝑐 =
180

= 0.833
Total volume = vol.I + vol.II + vol.III
= 50 + 100 + 150
= 300 cm³
Total surface area = 450 cm²