–

–
1. Conventional Molding Processes
Green Sand molding
Dry sand molding
FlasklessMolding

2. Chemical Sand Molding

Shell Molding
Sodium Silicate molding
No-Bake Molding

3. Permanent Mold Processes

Gravity Die Casting
Pressure Die casting
4.Special Casting Processes
▪Centrifugal Casting
▪Investment Casting
▪Continuous casting
▪Plaster Molding
▪Squeeze Casting
▪Evaporative Pattern Casting
▪Vacuum Sealed molding
▪Ceramics Shell Molding
▪Slush Casting
‑ ‑ ‑ ‑
‑
‑
Steps in shell‑molding: (6) two halves of the shell mold are assembled,
supported by sand or metal shot in a box, and pouring is accomplished;
(7) the finished casting with sprue removed
▪
▪
▪
Need for sodium silicate molding

Poor strength of green sand mold

Poor surface finish of green sand mold
Inability of green sand mold to retain small details

Molding materials for sodium silicate process

•Fresh silica sand

•Sodium silicate (binder)
•Hardener (CO2 gas,Portland cement,blast furnace slags
Types of sodium silicate molding process

1. Self hardened
Hardner: Portland cement,blast furnace slags,ferro silicon ,
Setting time: 2 hours to 24 hours

2. CO2 hardenened
Hardener:CO2 gas
Setting time:few minutes
✔

✔
•

•
✔

✔
✔

✔
✔In permanent mold casting, the mold is reused many
times
✔Mold material is metal or alloy
✔Also known as Die casting

Types of Die casting processes

Gravity Die casting

Pressure Die casting
Cold chamber pressure die casting
Hot chamber pressure die casting
•Uses a metal mold constructed of two sections designed for easy,
• precise opening and closing
•Molds used for casting lower melting-point alloys (Al, Cu, Brass)
are commonly made of steel or cast iron
•Molds used for casting steel must be made of refractory material,
due to the very high pouring temperatures
Steps in permanent mold casting: (1) mold is preheated and coated
Steps in permanent mold casting: (2) cores (if used) are inserted
and mold is closed, (3) molten metal is poured into the mold,
where it solidifies.

If difficult to remove core from casting, the sand-made core is used.

Such a process is called Semi-permanent mold casting
✔
✔
✔

✔
✔

✔
✔
Metal is melted in a container, and a piston injects liquid metal under high
pressure into the die
• High production rates - 500 parts per hour not uncommon
• Injection pressure: 7-35MPa
• Applications limited to low melting‑point metals that do not chemically
attack plunger and other mechanical components
• Casting metals: zinc, tin, lead, and magnesium
Cycle in hot‑chamber casting: (1) with die closed and plunger withdrawn,
molten metal flows into the chamber
Cycle in hot‑chamber casting: (2) plunger forces metal in chamber to flow into die
maintaining pressure during cooling and solidification.
 ‑

•
‑

•
 ‑

Cycle in cold‑chamber casting: (1) with die closed and ram withdrawn,
molten metal is poured into the chamber
 ‑

Cycle in cold‑chamber casting: (2) ram forces metal to flow into die,
maintaining pressure during cooling and solidification.
•
–
–
–
–

•
–
–

–
•
–
–
–
•

•
•
•
•
•
•
•
•

•
‑
•
–
–
–
– ‑

•
–
–
 ‑

• ‑
‑ ‑

•
•
–
– ‑
‑

•
–
–
•
–
–

1.
2.
•
–
–
–

•
–
–

–
–
•
•
•

•
•
–
–

– ‑

•
–
–
 ‑ ‑
•

•
•
–
– ‑
•
–

–
–