Casting/Founding

It is a process of pouring molten metal into a mould in a cavity of the

shape to be made and allowing it to solidify. As this is done in
foundry shop so it is also called founding.

Casting

Casting/Founding
Advantages of Casting:
Molten material can flow into very small section so
that intricate shapes can be made.
Any material can be cast (Ferrous and Non-
Ferrous)
Necessary tools are simple and inexpensive
Size and weight is not a limitation
Better dimensional accuracy and surface finish

Disadvantages of Casting:
Labor intensive process
Dimensional accuracy and surface finish is not
good in case of sand casting
 Patterns Patterns
A pattern is a model or the replica of the object (to be casted).

Objectives of a Pattern

1. Pattern prepares a mould cavity for the purpose of making a casting.

2. Pattern possesses core prints which produces seats in form of extra recess
for core placement in the mould.
3. It establishes the parting line and parting surfaces in the mould.
4. Runner, gates and riser may form a part of the pattern.
5. Properly constructed patterns minimize overall cost of the casting.
6. Properly made pattern having finished and smooth surface reduce casting
defects.
 Patterns Patterns
Advantages of wooden patterns
Common Pattern Materials
1. Wood can be easily worked.
1. Wood 2. It is light in weight.
3. It is easily available.
2. Metal The metals commonly used for pattern making are cast iron, brass and 4. It is very cheap.
5. It is easy to join.
bronzes and aluminum alloys 6. It is easy to obtain good surface finish.
3. Plastic Phenolic resin plastics are commonly used. Recently foamed plastic is also 7. Wooden laminated patterns are strong.
8. It can be easily repaired.
used.
4. Plaster This material belongs to gypsum family which can be easily cast and Disadvantages

worked with wooden tools and preferable for producing highly intricate casting. 1. It is susceptible to moisture.
5. Wax The commonly used waxes are paraffin wax, shellac wax, bees-wax, cerasin 2. It tends to warp.
3. It wears out quickly due to sand abrasion.
wax, and micro-crystalline wax. 4. It is weaker than metallic patterns.

Patterns Removable Patterns

Advantages of Removable patterns
1. Reusable
2. Can be used in machine moulding
On the basis of use patterns can be classified as: 3. Cavity produced can be inspected
4. Easy to handle
1. Removable pattern
Disadvantages of Removable patterns
2. Disposable pattern
1. Time required more
2. Finishing is not good
3. More metal is needed
4. Complex pattern with loose piece is difficult to
handle
 Disposable Patterns Patterns: Classification
Advantages of Disposable patterns
1.0 Time required less On the basis of physical structure there are many
2.0 Less metal needed patterns available
3.0 Mould making is simple
4.0 Finishing is good
Disadvantages of Disposable patterns
1.0 Not reusable
2.0 Cavity produced can not be inspected
3.0 Machine moulding is not possible
4.0 Patterns are difficult to handle
 Pattern
Allowances

Contraction from liquid to solid

Hot casting size Contraction from pouring to
A freezing temperature

Pattern size

B
Contracted final size

Total
Allowance

Shrinkage Allowance
 Draft Allowance
Draft Allowance

Interior Draft Allowance

 CORE CLASSIFICATION OF CORE

CLASSIFICATION OF CORE
Properties of Good Core

1. Permeability

2. Gas generation
Vertical Core
Horizontal Core 3. Collapsibility
Pattern

4. Thermal stability

5. Strength
Core

Casting
Balanced Core Drop Core
 Moulding Sand Moulding sand
Principal constituent:
Silica-86-90%
Aluminium- 4-8%
Iron oxide-2-5%
Smaller amount of Ti, Mn, Ca some alkaline component.
According to the nature moulding sand may be classified as:-
Natural sand- Natural resources like lake, river.
Synthetic sand- Artificial sand by mixing Clay free sand + binder+
other materials as required properties can be controlled easily.

Sand Testing
 Sand testing Permeability Test

Permeability Test Permeability Test

Classification of Casting Processes Classification of Casting Processes

Classification of Casting Processes OUR CONCENTRATION

 Shell Mould Casting
Sand Mixture (Dry silica sand 100 parts
Powdered phenol formaldehyde resin
Hot binder 2-8 parts
Clamp Pattern Wetting agent 0-1/4 parts) Flask Shells

Shell Mould Casting

Step Step 2
1 Clamp
Book: Rajender Singh Shell Ejector pin

Step 5
Baking sand
Step 4
Step 3

Advantages of Shell Mould Casting Disadvantages of Shell Mould Casting

 Applications of Shell Mould Casting

Lost Wax
Casting
Pipe Fittings, Valves etc. Cylinder Block. Book: P. N. Rao

Lost wax casting/Precision casting Lost wax casting/Precision casting

Step 3
Step 2
Step 1

Master Pattern of Master Mould

steel or brass Split mould is formed from galantine
or an alloy of low melting point
Step 4 Step 5 Materials for master mould:
1. Plaster of Paris or Gypsum
products for non-ferrous
Wax Pattern
castings
2. Ethyl silicate, Sodium silicate
and Phosphoric acid for steel
Master Mould filled with either
liquid wax or thermoplastic
castings
polystyrene resin 3. Sometimes fine grain silica
sand with binders
 Lost wax casting
Advantages of Lost wax casting:
1.Very smooth surface and high dimensional
accuracy.
2.Reproduction of surface details and
dimensions with precision.
3.No cores and loose pieces.
4.Very thin sections can be cast.
5.Complex shape is easily obtained.
6.No or little machining is needed.
Continuous
Casting
Book: P. N. Rao
Lost wax casting
Disadvantages of Lost wax casting:
1.Limited by the size and mass of the casting.
2.Expensive process.
3.Long time process.
4.Large floor space needed.
Applications:
1. Artifacts, Jewellery and surgical equipments.
2. Vanes and blades for gas turbine.
3. Bolts and triggers for fire arms.
4. Impeller for turbo chargers.
Continuous casting, Reciprocating type
 Continuous casting, Reciprocating type Continuous casting, Closed Horizontal type

Continuous casting, Wheel belt system Continuous casting, Wheel belt system

Belt Molten Metal

Metal Metal

Belt Belt

Solidified
metal strip

Wheel Wheel
 Centrifugal casting
In this casting molten metal is solidified while mould is revolving.

The metal solidifies under the pressure of centrifugal force which

cause the metal to take up the impression of the mould cavity.

Centrifugal casting Metals towards the periphery and gases and other materials
towards the axis of rotation.

Three centrifugal casting processes:

Book: P. N. Rao/ Rajender Singh 1. True centrifugal casting
2. Semi-centrifugal casting
3. Centrifuged or Pressure casting

True centrifugal casting True Centrifugal Casting

The wall thickness of cylindrical is governed by the quantity
of metal that is introduced into the spinning mould Rotating axis may be horizontal, vertical or inclined.
 Semi centrifugal casting Semi centrifugal casting

Same as true centrifugal casting but only Rotational speed is less

difference is that a central core is placed to than true centrifugal
form inner surface. casting
Centrifugal force aids in proper feeding of
mould cavities.
Flywheel, Gears etc.
Axis of spinning is always vertical.

Centrifuged or pressure casting Centrifugal casting

When casting shape is not axisymetrical.

A number of small jobs are joined together
on the revolving table.
Advantages:
Castings produced are sounder with dense structure, cleaner and the
foreign inclusions are eliminated completely.
Mass production is possible with less rejections.
Use of runners, risers and cores is eliminated.
Mechanical and physical properties are improved.
Low machining cost.
Thinner sections can be cast.
Any metal can be cast by this process.

Disadvantages:

Limited to only cylindrical and annular parts with a limited range of

sizes.
It involves high initial cost
Too high speed may result in surface cracks.
 Permanent mould casting
Metallic Mould of Cast Iron or steel
Without External Pressure, Also Called Gravity Die Casting

Die
Casting
Book: Rajender Singh

Permanent mould casting Permanent mould casting

Advantages: Disadvantages:

Free from sand and good surface finish.
Superior in hardness and mechanical properties.
Heavier density than sand casting
Less skilled labor needed.
Production rate is high.
Requires less space.
Number of rejection is less.
Not suitable for alloy of high melting point and large
size.
Limited to mass production of identical product.
Defects like stress and surface hardness produced due to
surface chilling effect.
Not flexible.
Mould maintenance cost is high.
 Die casting Die casting, Hot Chamber, Direct Air Pressure Type

Molten or semi-molten metal is poured under gravity or high pressure.

Pressure is maintained till solidification stage.
Die consists of two parts
1. Stationary
2. Movable or Ejector
Die casting machines are two types
1. Hot chamber die casting machine
Holding furnace is integral to machine
Used for lead, tin, zinc etc low melting point alloys.
Hot chamber machine has two types of arrangements:

a. Direct Air Pressure Type

b. Submerged Plunger Type
2. Cold chamber die casting machine
Metal is melted in a separate furnace and then poured
into machine
Used for aluminum, manganese etc.
High melting point alloy.

Die casting, Hot Chamber, Submerged plunger Type Die casting, Cold Chamber
 Die casting Die casting vs Permanent Mould Casting

Advantages:

1. Less floor space

2. Precision manufacturing and less machining cost
3. Thin sections of the order of 0.5 mm is possible
4. Improved surface finish
5. Less rejection, strong and dense metal structure
6. High production rate (800 castings per hour)

Disadvantages:

1. Cost of Die and equipments is high

2. Life of Die decreases rapidly due to high temperature
3. Only non-ferrous alloys are cast
4. Size is limited
5. Special skill required for die maintenance

Extrusion Moulding Injection Moulding

Injection Moulding

Casting Defects Casting Defects

Book: Rajender Singh
1. Blow holes 11.Drops
2. Shrinkage 12.Shot Metal
3. Porosity 13.Shift
4. Misruns 14.Crushes
5. Hot Tears 15.Rat-tails or Buckles
6. Metal Penetration 16.Swells
7. Cold shuts 17.Hard Spot
8. Cuts and washes 18.Run out, Fins and Flash
9. Inclusions 19.Spongings
10.Fusion 20.Warpage
 Casting Defects
Surface roughness caused due to too coarse moulding sand or high pouring
temperature.
In steel casting, iron is oxidized which reacts with silica to form rough
compounds
Scabs or buckles due to sand shearing from cope surface.
Occurs due to too fine sand, uneven ramming, high moisture, low running of
molten metal.
Casting Defects
Hot tears Cracks during solidification.
Caused by discontinuity of casting, excessive mould hardness, improper
metallurgical and pouring temperature control etc.
Cold-shots two metal stream meeting together are too cold to fuse properly.
Caused by slow pouring, improper gate design.
Casting Defects
Blow holes Internal voids as a result of excessive gaseous materials.
Caused by hard ramming, excessive moisture, low permeability, improper
venting, excessive gas producing ingredients.
Pinholes Surface reactions cause surface porosity or pinholes.
Magnesium reacts with water vapour and forms H2.
Casting Defects
Run outs Drainage of metal from cavity. Caused by too large pattern,
inadequate mould weights and excessive pouring pressure.
Fins Usually occurs at the parting of mould and core section. Caused by run out
of metals.
Internal air pockets Caused by pouring boiling metals.
Misruns some portion is not filled with metals. Caused due to low pouring
temperature, lack of fluidity of metals, too small gate etc.
 Casting Defects

There are many other defects resulting from

Improper ramming
slow feeding
poor design
metal contraction
gas generations etc.