THE PAPER ENGLISH

TO FULFILL TASKS ABOUT FOUNDRY CASTING

Lecturer Mrs. Rr. Poppy Puspitasari, S.T., M.T., Ph.D

Arranged by:
M. Al-ghazali (200514632003)
Ulfieda Anwar Ulhaq (200514632001)

S1 Mechanical Enginering Study Program

Majoring in Mechanical Engineering
Faculty of Engineering
State University of Malang
Malang
October 2020
 PRREFACE
First of all, special thanks to Allah SWT for blessing and grace, we can accomphlishing this
Technical English tasks endtitled “Foundry Casting” can be finished on time.
We made this assignment as a learning resource about “Foundry Casting” for Mechanical
Engineering Students. Hopefully this paper we write can help broaden our knowledge. We realize
that there are still many shortcomings in the preparation of this paper.
The purpose of writing this paper is to fulfill the duties of Mrs. Poppy Puspitasari S.T., M.T.,
Ph.d. in the S1 Mechanical Engineering field of Engineering Materials Knowledge course. In addition,
this paper also aims to add insight into the Ferro Material for readers as well as for writers.
Me and my group members would like to thank Mrs. Poppy Puspitasari S.T., M.T., Ph.D., as a
lecturer in the field of Mechanical Engineering S1 Mechanical Engineering subject who gave this
assignment so that they can add knowledge and insight according to the field of study we are
working on.
I and my group members would also like to thank all those who have shared some of their
knowledge so that we can complete this paper.
My group members and I realized that the paper we wrote was far from perfect. Therefore,
we will wait for constructive criticism and suggestions for the perfection of this paper.

Surabaya, 6 November 2020

Author

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 TABLE OF CONTENT

Preface...........................................................................................................................................i

Table of Contents...........................................................................................................................ii

Chapter I Intoduction
1.1 Background of the paper.........................................................................................................1
1.2 Problem formulation................................................................................................................1
1.3 Porpuse Of The Paper..............................................................................................................1

Chapter II Discussion
2.1 Meaning Of Casting..................................................................................................................2
2.2 Casting Methods.......................................................................................................................2
2.3 Defect Of Casting......................................................................................................................8

Chapter III Clossing

3.1 Conclusion................................................................................................................................11

Refrence.........................................................................................................................................12

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 CHAPTER I
INTRODUCTION
1.1 Background Of The Paper
It dates back to approximately 4,000 BC, with the exact year unknown. When people find
out that castings are made from molten metal, they are poured into a mold, then allowed to
cool and freeze. Where metal casting technology is used for the metal forming process and
various casting methods have been developed to date. This is because metal has hard and strong
properties so that it has a longer service life. Metal was originally used to make jewelry from
hammered gold or silver, and later to make weapons or pirate eyes by hammering copper.
Then the casting process becomes an integral part of making various types of tools. In the
course of the casting process has been developed over time, each of which has its own
characteristics and applications to meet the requirements of special engineering services. Most
parts and components are molded through a casting process, for example block engines,
crankshafts, automotive and electric rail components, agricultural and railroad equipment, pipe
and plumbing fittings, electrical equipment, gun barrels, frying pans, office equipment, and very
large components for hydraulic turbines.

1.2 Problem Formulation

1. What is the meaning of casting
2. How many casting methods?
3. how many kinds of casting defects?

1.3 Purpose Of The Paper

1. Describe the meaning of casting
2. Describe the casting methods
3. Describe the casting defects

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 CHAPTER II
DISCUSSION
2.1 Meaning Of Casting
Casting is the most important process in which the method is widely used for fabricating,
restoring metal outside the mouth. Foundry technique is one of the oldest and most advanced
metallurgical seniors. The basic principle in casting is
'it's a sticky liquid'.
The process consists of eating a wax pattern with a mold made of heat investment material,
eradicating resistant wax and inserting molten metal into a mold called "SPRUE". So that during
the casting process the possibility of defects occurs. Minor flaws can prevent but causing major
damage can lead to more investment costs. To produce quality cast results, high quality patterns
are needed, both in terms of construction, dimensions, material patterns, and other accessories.
There are four factors that influence or are a characteristic of the casting process, namely:
1. The flow of molten metal into the die cavity.
2. There is heat transfer during freezing and cooling of the metal in the mold.
3. The influence of the mold material.
4. Freezing of metals from a liquid state.

Source: https://www.industrystar.com/blog/2016/08/key-considerations-sourcing-castings/
2.2 Casting Methods
1. SAND CASTING (High Temperature Alloy, Complex Geometry, Rough surface)
Sand casting is often utilised in industries For Instance:automotive, aerospace and
design industries etc. Tomake parts of comprised of Iron, bronze, brass andaluminium. The
metal of require is gets melted in afurnace at desired temperatures and poured into a
mouldcavity formed out of sand. This process is preferred because of inexpensive and
relatively free of cost However, flaws are very common in sand cast parts andthese affects
the properties of castings.
Stages of casting metal with sand molds:
• Pattern making, according to the shape of the castings to be made;
• Print sand preparation;
• Mold making;
• Core making (if required);
• Metal smelting;
• Liquid metal pouring into molds;

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 • Cooling and freezing;
• Disassembly of the sand mold;
• Cleaning and inspection of castings;
• The casting process is complete.
Types of patterns:
a. Solid pattern: Solid pattern is made similar to the geometry of cast objects taking into
account shrinkage and allowance for machining. Although making this pattern is easy, it is
difficult to make a mold, such as making a dividing line between the top of the mold (cope)
and the bottom of the mold (drag). Likewise, to build a channel system (riser), a trained
workforce is required;
b. Split pattern: Consists of two parts that are adjusted to the dividing line (cleavage) of the
mold. Usually used for cast objects that have more complex geometries with intermediate
production quantities. The pattern of making molds is easier than using solid shapes.
c. Match-plate pattern: Used for a larger amount of production. In this pattern, two halves of
the split pattern are each placed on opposite sides of a wooden plank or iron plate.
d. Cope and drag pattern: This pattern is almost the same as the connecting board pattern,
but in this pattern the two halves of the split pattern are attached to a separate board. This
pattern is also commonly equipped with an inlet and riser system.
Sand mold classification:
1. Wet sand mold, made from a mixture of sand, clay, and water.
2. Dry sand mold, made using organic binder, and then the mold is burned in an oven with a
temperature of 204 to 306 Celsius. Burning in the oven can strengthen the mold and harden
the surface of the mold cavity.
3. Dry skin mold, obtained by drying the surface of wet sand with a depth of 1.2 cm to 2.5
cm on the surface of the mold cavity. a special adhesive should be added to the sand
mixture to strengthen the surface of the print cavity.

2. DIE CASTING
Die casting is a metal casting process characterized by forcing high pressure molten
metal into the mold cavity. The mold cavity is created using two hardened tool steel molds
that have been machined and work similarly to an injection molding during the process.
Casting and molding equipment represent large capital costs and this tends to limit the
process to high-volume production. The manufacture of spare parts using mold casting is
relatively simple. Th
There are two types of casting that are very commonly used in the manufacture of metal
objects. The difference is in the principle of the location where the material is melted. So
what are the types of casting, including:
a. Hot Camber (HCDC)
In the hot chamber type, it is a machine that includes a melting unit and an injection unit in
one piece of equipment. The melting unit is a place that is used as a metal melting furnace.
The injection unit is useful for providing very high pressures in the casting process. A molten
metal or main material present in a smelting unit. It will be directly injected into the
injection unit. In this process, the pressure applied is around 5,600 and even up to 22,000
psi.
b. Cold Camber (CCDC)
Unlike the hot chamber, this tool has a melting unit and injection unit for two different
components, not in one tool. So, in this tool the liquid metal needs to be poured first into
the melting unit into the ladle. And later it will be carried by the injection unit machine to be
poured and injected into the die. In cold chamber type tools or machines, it has a metal
injection system that only comes into direct contact with the molten metal for a very short

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time. That way, this system is able to work or more durable working hours. Generally, this
type of machine requires a greater pressure to fill and seal the various cavities.
Any metal printing machine is certainly composed of several components. These are the
components of the die casting are:

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 1. Melting Unit
The first component is the melting unit. Which becomes a container to hold molten metal.
Apart from being able to accommodate, this machine part can also melt metal. This
component is very important in the metal molding system.
2. Injection Unit
Next is the injection unit. In this unit functions to carry out a transfer of liquid metal. What
was originally in the melting unit is then brought into the die. Then there is either an
injection or a high pressure applied. In order to print or form an object.
3. Die Unit
Die units are a very common permanent mold made of metal. This tool has several cavities
that are useful for giving shape to castings. Which will later be filled with molten metal. This
mold consists of 2 other units, between a fixed die and a movable die.

3. INVESTMENT CASTING
Investment casting is a manufacturing process in which a wax pattern is coated with
a refractory ceramic material. After the ceramic material hardens, the internal geometry
takes the form of a casting. The ax was melted and molten metal was poured into the cavity
where the wax pattern was. Metal hardens in ceramic molds and in metal castings break.
The investment casting process:
1. Candle patterns are produced.
2. Several patterns are attached to the sprue to form a pattern tree.
3. The tree pattern serves with heat resistant lining material.
4. A mold is formed.
5. The mold is turned over and heated to melt the wax and let it drip out of the cavity.
6. The mold is heated to a high temperature to ensure that all contaminants are removed.
The hot mold also helps the molten metal flow more easily into the cavity mold. Liquid metal
is poured.
7. The mold is detached from the cast product. The product parts of the sprue.

Source: https://bernierinc.com/investment-casting/

4. PERMANENT CASTING
Permanent mold casting is a metal casting process that uses a reusable mold
("permanent mold"), usually made of metal. The most common processes use gravity to fill
the mold, however gas pressure or avacuum is also used. Variations in the typical gravity
casting process, called slurry casting, result in hollowcasting. Common foundry metals are

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 aluminum, magnesium, and copper alloys. Other materials including metal, zinc, and
lead alloys as well as iron and steel are also cast graphite molds.
Steps In Permanent Mold Casting
1. The mold is preheated and coated for lubrication and heat dissipation

2. The core (if one is used) is inserted and the mold is closed

3. The molten metal is poured into the mold to harden

4. Mold is opened

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 Source: https://www.academia.edu/33502188/Permanent_Mold_Casting_Processes

5. CENTRIFUGAL CASTING
Centrifugal casting or rotocasting is a casting technique typically used for molding
thin-walled cylinders. It is used to print materials such as metal, glass, and concrete. It is
noted for the high quality of the results that can be achieved, especially for the precise
control of the metallurgy and crystal structure. In the centrifugal casting process, molten
metal is poured into a rotating mold. The dice can rotate either on a vertical or horizontal
axis depending on the configuration of the part desired. Ring and cylinder shapes are printed
vertically; tubularshapes are made by horizontal centrifugal process. Either process can be
used to produce multiple parts from one casting. External structures and shapes can be
installed in place to significantly reduce post-processing including machining or fabrication.
The casting process is usually performed on a horizontal centrifugal casting machine
(vertical machines are also available) and includes the following steps:
1. Mold preparation - The walls of a cylindrical mold are first coated with a refractory
ceramic coating, which involves a few steps (application, rotation, drying, and baking). Once
prepared and secured, the mold is rotated about its axis at high speeds (300-3000 RPM),
typically around 1000 RPM.
2. Pouring - Molten metal is poured directly into the rotating mold, without the use of
runners or a gating system. The centrifugal force drives the material towards the mold walls
as the mold fills.
3. Cooling - With all of the molten metal in the mold, the mold remains spinning as the metal
cools. Cooling begins quickly at the mold walls and proceeds inwards.
4. Casting removal - After the casting has cooled and solidified, the rotation is stopped and
the casting can be removed.
5. Finishing - While the centrifugal force drives the dense metal to the mold walls, any less
dense impurities or bubbles flow to the inner surface of the casting. As a result, secondary
processes such as machining, grinding, or sand-blasting, are required to clean and smooth
the inner diameter of the part.

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 Source: https://www.custompartnet.com/wu/centrifugal-casting

2.3 Defect Of Casting

1. BLOWHOLES
Blowholes are one of the major casting failures caused due to the increase and complexity of
gases during the casting process. The filling of the mold cavity layer is replicated,
accompanied by calculations and the instantaneous display of the metal temperature and
gas pressure created in the mold cavity. There are different types of effects created in sand
casting. The high defect content in casting is due to gas emission. One of the main casting
defects caused by gas is a hole (gas hole). The gas holes are the small holes and blowholes.
The blowhole is a smooth, round cavity and does not touch the external casting surface.

Source:
https://www.academia.edu/33109550/A_Critical_Review_on_Casting_Types_and_Defects

2. SHRINKAGE
Shrinkage is a type of casting defect with irregularities in the metal casting process and due
to a lack of design and insufficient feed metal. Some defects are acceptable while others can
be repaired, otherwise they must be destroyed. There are two types of shrinkage defects,
namely: open shrinkage defects and closed shrinkage defects. Shrink defects open to the
atmosphere; There are two types of open air defects: pipes and curved surfaces. Pipes form
on the surface of the casting and burrow into the casting, while cavedsurfaces are shallow
cavities that form on the surface of the casting. Closed shrinkage defects, also known as
shrinkage porosity, are defects that form in casting.

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 Source:
https://www.academia.edu/33109550/A_Critical_Review_on_Casting_Types_and_Defects

3. HOT TEARS/CRACK
These defects can be caused in the weaker part ofsections and in cold dies, low metal
temperature, dirtymetal, lack of venting, other possible defects are gas porosity, shrinkage
porosity, weaker sections and flowmarks.

4. SAND INCLUSSION
Sand Inclusion is most common casting defects which isnothing but cracks of sand while
preparing mouldsection manifests itself near casting edges to create suchfailure. Sand
inclusion and slag inclusion are also calledas scab or blacking scab. They are inclusion
defectslooks like there are slags inside of metal castings.Irregularities formed in sand
inclusions, close to thecasting surface.

5. DEFECTIVE SURFACE
Line formation due to molten metal flow forming in a pattern of line based structures which
appear in channelscalled as defective surface.

Source:
https://www.academia.edu/33109550/A_Critical_Review_on_Casting_Types_and_Defects

6. MISMATCH
Mismatch in mould defect which can be mainly seen because of the changing moulding
flashes. It will causethe dislocation at the parting line.

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Source:
https://www.academia.edu/33109550/A_Critical_Review_on_Casting_Types_and_Defects

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 CHAPTER III
CLOSING
3.1 Conclusion
Various types of possible defects in casting work joints have been reviewed. This study is
useful for industries where casting is carried out as a manufacturing process. The whole
study is to minimize casting defects and improve casting process standards.

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 REFRENCE
1. Kalpakjian Serope. 2009. Manufacturing Engineering and Technology 6th Ediotion

2. Makama Muhammad Nura. Permanent Mold Casting Processes. Accessed on 7 November

2020. https://www.academia.edu/33502188/Permanent_Mold_Casting_Processes

3. International Journal Of Scientfic Research In Science, Engineering and Technology IJSRSET

(2017). Accessed on 7 Nvember 2020.
https://www.academia.edu/33109550/A_Critical_Review_on_Casting_Types_and_Defects

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