MANUFACTURING PROCESSES

Metal Casting

Department of Mechanical Engineering

HITEC University, Taxila Cantt
This Lecture
 Permanent Mold Casting
 Slush Casting
 Low Pressure/ Vacuum Casting
 Hot and Cold Chamber Die Casting
 Centrifugal Casting
 Types of Furnaces for Casting
 Casting Defects
 Design Considerations

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Furnaces
 Several types of furnaces are most commonly used in
foundries
 Cupolas
 Crucible Furnaces
 Induction Furnaces

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Cupolas
A vertical cylindrical furnace with a
tapping spout at the base. They are used
to melt Cast Irons.
 It consists of a large shell of steel plate
lined with refractory
 The charge consist of Iron , coke, flux
 Iron is usually a mixture of pig iron and
scrap

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Cupolas
 Coke is the fuel used to heat the
furnace
 Flux is a basic compound like
Limestone that reacts with coke ash
and other impurities to form slag
 The slag protects metal from
reaction and reduce heat loss
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Crucible Furnaces
 These furnaces melt the metal without
direct contact with a burner
 Also called indirect fuel fired furnaces
 Three types are commonly used in
industries
 Lift-out type
 Stationary
 Tilting

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Lift out Crucible Furnace

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Stationary Pot Crucible Furnace

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Tilting Pot Crucible Furnace

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Induction Furnace

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Casting Defects
 There are numerous opportunities for
things to go wrong in a casting operation,
resulting in quality defect in the cast
product.
 Some defects are common to any and all
casting processes
 A brief description of these defects is
discusses next
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Misruns

 A misrun is a casting that has solidified

before completely filling the mold
cavity. Typical cause include
 Fluidity of the molten metal is insufficient
 Pouring temperature is too low
 Pouring is done too slowly
 Cross-section of the mold cavity is too
thin

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Cold Shut

 A cold shut occurs when two

portions of the metals flow
together but there is a lack of
fusion between them due to
premature freezing.
 Its causes are similar to those of
misrun

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Shrinkage Cavity

 A depression or an internal void

in the casting caused by
solidification shrinkage that
restricts the amount of molten
metal available in the last region
to freeze.

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Cold Shots

 When Splattering occurs during

pouring, solid globules of metal
are formed that become
entrapped in the casting.
 Pouring procedures and gating
system designs that avoid
splattering can prevent this
defect

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Microporosity

 Small voids distributed

throughout the casting
caused by localized
solidification shrinkage of
the final molten metal .
 Usually associated with
alloys

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Hot Tearing

 Also called hot cracking,

occurs when the casting is
restrained from contraction by
an unyielding mold during the
final stages of solidification or
early stages of cooling after
solidification

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Casting defects for Sand Casting
 Some defects are related to the use of sand molds
 Sand blow
 Pinhole
 Sand wash
 Scab
 Penetration
 Mold shift
 Core shift
 Mold crack

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Sand Casting Defects

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Blow holes & Porosity

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Shrinkage, Misruns & Hot tears

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Metal Penetration, Cold Shuts & Sand Wash

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Mold & Core Shifts

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Comparing Different Casting Types

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Design Rules for Casting
 Design the part so that the shape is cast
easily.
 Select a casting process and material suitable
for the part, size, mechanical properties, etc.
 Locate the parting line of the mold in the
part.
 Locate and design the gates to allow uniform
feeding of the mold cavity with molten metal.

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Design Rules for Casting
 Select an appropriate runner
geometry for the system.
 Locate mold features such as sprue,
screens and risers, as appropriate.
 Make sure proper controls and good
practices are in place.

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Riser Design
 The riser must not solidify before the
casting.
 The riser volume must be large enough
to provide a sufficient amount of liquid
metal to compensate for shrinkage in the
cavity.
 Junctions between casting and feeder
should not develop a hot spot where
shrinkage porosity can occur.
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Riser Design
 Risers must be placed so that the liquid metal
can be delivered to locations where it is
most needed.
 There must be sufficient pressure to drive
the liquid metal into locations in the mold
where it is most needed.
 The pressure head from the riser should
suppress cavity formation and encourage
complete cavity filling.

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Design Rules for Casting
 Sharp corners, angles and fillets should
be avoided because they act as stress raisers
and may cause cracking and tearing of the
metal during solidification.
 Section changes should be smooth. The
location of the largest circle that can be
inscribed in a particular region is critical.
 They will have the lowest cooling rate and are
termed as hot spots.

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Eliminating Hotspots

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Design Rules for Casting

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Design Rules for Casting

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Design Rules for Casting

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Good and Poor Casting Designs

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