Introduction to Metal Casting

Dr. Suyitno, ST., MSc.

 High Pressure Die Casting

Principle of the Pressure Die Casting Process 3201.00.09

Example of High-Pressure Die Casting (Gear)
Machine for Turning Over Large Moulds
 Cosworth Process
(Low Pressure Sand Casting)

Melting Furnace

Zircon
Sand Mould
Electro-Magnetic
Pump

Holding
Furnace

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Schematic of the Cosworth Process 3201.00.21
Training in Aluminium Application Technologies
Cosworth Foundry in Worcester, UK, Showing the 3201.00.22
Lightweight Foundry Equipment Design
Rotary Engine Housing with Thick (15 mm)
and Thin (2 mm) Sections
Aerospace Sand Casting: Pilot`s Ejector Seat Frame
Aerospace Sand Casting: Air Intake for a
Turbo-Engine (Rolls Royce)
Aerospace Sand Casting: Air Intake for a
Turbo-Engine (France)
Schematic of the Squeeze Casting Process
3201.00.27
(Sometimes Also Called Squeeze Forming)
GKN Sankey Squeeze Casting Machine (Telford, UK)
Typical Examples of Squeeze Casting Product Forms
 Die casting processes

High pressure Low pressure Gravity Squeeze

die casting die casting die casting casting

~ 50% ~ 20%

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Die Casting Processes
Schematic view of high pressure die casting machine

Fixed platen
Die
Bolster
Moving platen
Casting

Ejectors Shot sleeve

Gate

Piston

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Schematic View of High Pressure Die Casting Machine
Schematic view of the low pressure die casting process
Moving platen

Dies

Pressurising gas
Metal fill
Fill stalk

Crucible

alu Schematic View of the Low Pressure

Die Casting Process
 Schematic view of gravity die casting
Pouring basin Casting
Feeder

Metal core
Filling
system

Sand core

Gate

Die location Core Print

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Schematic View of Gravity Die Casting
Stages in investment (low wax) casting

Make wax pattern in die

Assemble patterns onto 'tree'

Build up ceramic shell mould

Dewax and fire shell

Pour metal and allow to solidify

Remove shell

Separate castings from runner system and fettle

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Stages in Investment (Low Wax) Casting
Stages in the 'lost foam' process

Produce expanded polystyrene pattern

Assemble patterns onto runner system

Coat with ceramic slurry and dry

Embed in sand and vibrate to consolidate

Pour metal

Remove from sand

Clean and fettle castings

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Stages in the 'Lost Foam' Process