Casting and applications

• Centreline feeding resistance (CFR) means ratio of time of solidification At mould Centre line
of casting to total solidification time of casting .
• If CFR value is high, it means that , Material is difficult to be fed .
• Which of the following property is required for good wax pattern: High wettability
• The inner surface of the pattern requires more draft than the outer surface.
• More draft should be provided for hand moulding compared to machine moulding.
• Percentage of water used in clay is : 8 – 15%
• Major function of vent wire is that : To provide permeability to the mould
• Full mould casting process is also known as: Evaporative pattern casting
• In three boxes moulding the middle box is known as cheek. ( In between cope and drag)
• In semi permanent mould casting sand core is used.
Foundry equipments
• The sand is packed on pit moulds with snd slingers.
• Drawspike is used to remove the pattern from the mould.
• Dowel pins are used for aligning two halves of mold.
• Muller is used for mixing sand.
• Shot blasting is Process of cleaning castings.
• A swab is used in foundry for moistening the sand.
• A stick is a hand tool for repairing mould in foundry shop
• The grain size of moulding sand is expressed in terms of grin fitness number.
• Shatter test is conducted to measure of sand .
• A gagger is L shaped metal accessory used in floor moulds to support hanging bodies of
sand in cope.
• Bellows are Used in foundry for blowing loose sand from cavities and surface of the mould.
• A gooseneck is used for the pumping of liquid metal into the die cavity.

Colour code and pattern

• Black Colour : The surfaces which are to be left unmachined are painted with black colour.
• Red Colour : The surfaces which are to be machined are painted with Red colour.
• Yellow Colour : The core prints and seats for loose core prints are painted with Yellow colour.
• Yellow base with Red Stripes : The seats for loose pieces are marked with red strips on yellow
base.
• Yellow base with Black Strips : The stop offs are indicated by diagonal black strips on yellow
base.
• No colour : The parting surfaces is indicated by no colour.
Pattern
• Pattern is used to produce a number of castings : gatted pattern  
• pattern used for mass production or When small castings are to be produced in large
numbers : match plate pattern
• Follow board pattern are used to cast structurally weak portions.
• Sweep patterns are used for Circular shape objects.

Allowance
Grey cast iron                7 to 10.5.
Aluminium                    . 18
Bronze                             10.5 to 21
Brass                               14
• Distortion allowance is not provided in the following shape of casting : O
1. Silica sand : withstand high temp.
2. Coal dust : Helps in cooling the mould
3. Clay : Impart necessary bond to the moulding sand
4. Water : Increase adhesiveness
• Crucible furnace is used for melting of Non ferrous metal.
• In casting, scrabs or buckles occurs due to Sand casting from the cope surface.
•

1}Temporary mould or Expandebal mould

A. Investment Casting
• Molten wax is used as the pattern material
• Prepared pattern is dipped into slurry made by suspending fine ceramic materials like sodium
silicate & liquid ethyl silicate
• In the process of stuccoing, dry refractory grains such as zircon or silica are stuccoed on the
liquid ceramic coating.
• Mercury is used in place of wax for pattern then is kept at temperature below -38 ⁰C.(-57
⁰C freezing point)
• mass of casting < 5Kg
• Jewellery and surgical instruments , vanes and blades for a gas turbine, shuttle eyes for
weaving, wave guide for radars and impellers

B. Full moulding or lost foam process or evaporative pattern , cavityless pattern

• Polystyrene, plastics,epoxy ,foam
•
C. CO2 moulding
• Strength is required in moulding sand in large casting.
• also known as sodium silicate process is one of the widely used processes for preparing of
moulds and cores.
• sodium silicate produces silica gel which has better bonding properties also used to
eliminate water acts as binder.
• not economical than the green sand moulding.
• moulds and cores of varied sizes and shapes can be formed

D. Shell moulding
• Phenol formaldehyde Resins ( thermosetting resin ) sand dried silica sand
• shell moulding sand, dry and fine sand that is completely free of the clay is used
• Too much fine a grain size requires
• Thickness of shell depends on dwell time
• Dump box used to the formation of shell mould in the shell moulding procedure
• zinc stearate & calcium stearate : flowability
• Casting size < 200kg
• The thickness of shells in shell moulding is 0.3 to 0.6mm  
• Grey cast iron : most time used
• Cylinder block IC engine
• Rocker arm
• Valve plate of refrigerator

2} Permanent mould casting

• In permanent mould casting, the molten metal is poured under gravity.
• In permanent moulds, castings are capable of maintaining clearance of the order of 0.06 to
0.3mm.
• Used for small casting
• Large scale production
• Metallic core is not preferable that the sand core, because the metallic core cannot be
complex with undercuts and the like.

A. Die casting
• Only certain non-ferrous alloys can be cast economically.
• Very high production rates are possible.
1. hot chamber die casting : melting unit is an integral part of machine , Alloys of lead, tin, and
zinc , low melting point metals can be cast
2. cold chamber die casting : melting chamber is an external part of machine , High melting
point metals can be cast :
3. Gravity die casting : grey cast iron mostly used , good surface finish of the order of 4 micron
Apps : stators, gear blanks, aircraft fittings
• For small volume production of aluminium and magnesium, mould made of graphite is
preferred.
• A large number of castings around 100~250,000 can be produced easily without any
in-between maintenance
B. Centrifugal Casting
• Impurities are collected in the centre of casting
1. Semi centrifugal casting : Fly wheels, track wheels and gears (core is used) , Water pipes of
large length and diameter.
2. Centrifuged casting : used for non symmetrical castings
3. True centrifugal casting : Cast iron pipes and cylindrical barrels

C. Slush casting
• When a solid shell of sufficient thickness has formed, remaining liquid is poured out
• Bronze moulds are used in some cases of the slush casting when the better surface finish of
the exterior part is required
• Ornaments, toys and statue of low melting alloys
• Thin casting
• Hallow thin casting
• Hallow statues
• Toys
• Decorative items
• Thin ornaments
• Lamp shades
• boots, shoes and automotive products, such as protective skin coatings on arm rests, head
rests and crash pads.
• High melting point material like al and brass not used .

D. Sqeeze casting
• Also known as liquid metal forging
• Brake shoe made by Al
• Bush made up of brasd and bronze
• To produce non ferrous castings having mechanical properties comparable with forgings.
• to make the castings of compact size with good strength.
• Pressure : 50 to 140 MPa
Classification of Moulding sand according to their use:

1: Green sand : ( tempered sand ). It is a mixture of sand with 20 to 30 % clay, water 6 to 10 %.
used for small size casting of ferrous and non-ferrous metals.
2: Dry Sand
The green sand moulds when baked or dried before pouring the molten metal are called dry
sand moulds. The dry sand moulds have greater strength, rigidity and thermal stability. These
moulds used for large and heavy casting.
3: Loam Sand
A mixture of 50 percent sand grains and 50 percent clay is called loam sand. It is used for loam
moulds of large grey iron casting.
4: Facing Sand
A sand which is used before pouring the molten metal, on the surface is called facing sand. It is
specially prepared sand from silica sand and clay.
5: Backing or Floor Sand
A sand used to back up the facing sand and not used next to the pattern is called backing sand.
It is also known as black sand due to its colour.
6: System Sand
A sand employed in mechanical sand preparation and handling system is called system sand.
This sand has high strength, permeability and refractoriness.
7: Parting Sand
A sand employed on the faces of the pattern before the moulding is called parting sand. The
parting sand consists of dried silica sand, sea sand or burnt sand.
8: Core Sand
Thus the sand used for making these cores is called core sand. It is sometimes called oil sand.
It is the silica sand mixed with linseed oil or any other oil as binder.

Defeacts
• Swell
1. Enlargement of molten cavity
2. Improper ramming
3. The sand sould be properly ram
•

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