Metal Casting Processes

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By Tri Prakosa

FAKULTAS TEKNIK MESIN DAN DIRGANTARA

INSTITUT TEKNOLOGI BANDUNG
 Casting Methods
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• Sand Casting • Investment Casting • Die Casting

High Temperature Alloy, High Temperature Alloy, High Temperature Alloy,
Complex Geometry, Complex Geometry, Moderate Geometry,
Rough Surface Finish Moderately Smooth Surface Smooth Surface
Finish

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 Summary of Casting Processes
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 Typical Cast Parts
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(c)

(a)

(b) (d)

(a) Typical gray-iron castings used in automobiles, including the transmission valve body
(left) and the hub rotor with disk-brake cylinder (front). Source: Courtesy of Central Foundry
Division of General Motors Corporation. (b) A cast transmission housing. (c) The Polaroid
PDC-2000 digital camera with a AZ191D die-cast high-purity magnesium case. (d) A two-
piece Polaroid camera case made by the hot-chamber die-casting process. Source:
Courtesy of Polaroid Corporation and Chicago White Metal Casting, Inc.
 Characteristics of Casting
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 Production Steps in Sand-Casting
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Outline of production steps in a typical sand-

casting operation.
 Cetakan Pasir (Sand Mold)
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Schematic illustration of a sand mold, showing

various features.
 Sand Casting
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Description: Tempered sand is packed into wood or metal pattern halves,

removed form the pattern, and assembled with or without cores, and
metal is poured into resultant cavities. Various core materials can be
used. Molds are broken to remove castings. Specialized binders now in
use can improve tolerances and surface finish.
Metals: Most castable metals.
Size Range: Limitation depends on foundry capabilities. Ounces to many
tons.
Tolerances:
Non-Ferrous  1/32 to 6
Add  .003 to 3,  3/64 from 3 to 6.
Across parting line add  .020 to  .090 depending on size.
(Assumes metal patterns)
Surface Finish:
Non-Ferrous: 150-350 RMS
Ferrous: 300-700RMS
Minimum Draft Requirements:
1° to 5°
Cores: 1° to 1 1/2°
Normal Minimum Section Thickness:
Non-Ferrous: 1/8 - 1/4
Ferrous: 1/4 - 3/8
Ordering Quantities: All quantities
Normal Lead Time:
Samples: 2-10 weeks
Production 2-4 weeks A.S.A.

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 Distribusi temperatur cetakan
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http://www.sutcast.com/Libraries/Events_2010/Module-m.sflb.ashx
 Lempeng Pola (Pattern Plate)
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A typical metal match-plate pattern used in

sand casting.
 Design for Ease of Removal from
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Mold

Taper on patterns for ease of removal from

the sand mold
 Sand Cores
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Figure 11.6 Examples of sand cores showing core prints and chaplets to support cores.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Vertical Flaskless Molding
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(c)

Figure 11.7 Vertical flaskless molding. (a) Sand is squeezed between two
halves of the pattern. (b) Assembled molds pass along an assembly line
for pouring. (c) A photograph of a vertical flaskless molding line. Source:
Courtesy of American Foundry Society.
 FTMD - ITB

Sequence of
Operations for
Sand-Casting

Schematic illustration of the sequence of operations for sand casting. (a) A mechanical drawing of
the part is used to generate a design for the pattern. Considerations such as part shrinkage and
draft must be built into the drawing. (b-c) Patterns have been mounted on plates equipped with
pins for alignment. Note the presence of core prints designed to hold the core in place. (d-e) Core
boxes produce core halves, which are pasted together. The cores will be used to produce the
hollow area of the part shown in (a). (f) The cope half of the mold is assembled by securing the
cope pattern plate to the flask with aligning pins and attaching inserts to form the sprue and risers.
Continued on next slide.
 FTMD - ITB
Sequence of
Operations for
Sand-Casting,
Con’t.

(g) The flask is rammed with sand and rthe plate and inserts are removed. (h) The drag half is
produced in a similar manner with the pattern inserted. A bottom board is placed below the drag
and aligned with pins. (i) The pattern , flask, and bottom board are inverted; and the pattern is
withdrawn, leaving the appropriate imprint. (j) The core is set in place within the drag cavity. (k)
The mold is closed by placing the cope on top of the drag and securing the assembly with pins.
The flasks the are subjected to pressure to counteract buoyant forces in the liquid, which might lift
the cope. (l) After the metal solidifies, the casting is removed from the mold. (m) The sprue and
risers are cut off and recycled, and the casting is cleaned, inspected, and heat treated (when
necessary). Source: Courtesy of Steel Founder’s Society of America
 Shell-Molding Process
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The shell-molding process, also called dump-box technique.

 Shell Mold Casting
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http://www.custompartnet.com/wu/shell-mold-casting
 Shell Mold Casting
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Kelebihan dibanding sand casting:

 Toleransi dimensi lebih sempit,
 Permukaan produk lebih halus
 Lebih Murah
Contoh Produk:
 Gear housing
 Cylinder head
 Precision Casting
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 Jenis-jenis precision casting:

 Plaster-mold casting
 Ceramic-mold casting
 Investment casting

 Contoh produk:
 Komponen kunci
 Roda gigi
 Katup
 Fitting
 Tooling
 Perhiasan
 Plaster-mold Casting
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Bahan mold: plaster of paris (gypsum

atau kalsium sulfat), ditambah: talc dan
tepung silika
Pattern (pola mold) dibuat dari:
aluminium paduan, plastik thermosetting,
kuningan atau seng paduan.
Bahan benda kerja: Aluminium,
Magnesium, Seng, dan paduan berbasis
tembaga
 Sequence of Operations in Making a
Ceramic Mold
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Sequence of operations in making a ceramic mold. Source: Metals

Handbook, Vol. 5, 8th ed.
− Proses mirip dengan plaster-mold casting, tetapi bahan mold
adalah material refraktori sehingga dapatdigunakan untuk
temperatur tinggi
− Contoh produk: impeller, pahat potong, dies untuk metal
working, mold untuk komponen plastik dan karet
 Expendable Pattern Casting
(Evaporative-pattern casting/loss foam
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casting)

Schematic illustration of the expendable pattern casting process, also known as

lost foam or evaporative casting.
 Expandable-Pattern Casting Process
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Schematic illustration of the expandable-pattern casting process, also known as

lost-foam or evaporative casting.
 Expandable-Pattern Casting Process
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Contoh produk:
 cylinder heads
 engine blocks
 crank shafts
 brake components
 Manifolds
 machine bases
Bahan pola: polystyrene
 Evaporative Pattern Casting of an Engine
Block
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(a) (b)
(a) Metal is poured into mold for lost-foam casting of a 60-hp. 3-cylinder marine
engine; (b) finished engine block. Source: Courtesy of Mercury Marine.
 Investment (loss wax) casting Process
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Schematic illustration of investment casting (lost-wax) process. Castings by

this method can be made with very fine detail and from a variety of metals.
Source: Courtesy of Steel Founder’s Society of America.
 Investment Casting Process
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http://www.custompartnet.com/wu/images/investment-casting/investment-casting.png
 Integrally Cast Rotor for a Gas Turbine
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Investment casting of an integrally cast rotor for a gas turbine. (a) Wax pattern
assembly. (b) Ceramic shell around wax pattern. (c) Wax is melted out and the
mold is filled, under a vacuum, with molten superalloy. (d) The cast rotor,
produced to net or near-net shape. Source: Courtesy of Howmet Corporation.
 Comparison of Investment-Cast and
Conventionally Cast Rotors
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Cross-section and microstructure of two rotors: (top) investment-cast; (bottom)

conventionally cast. Source: Advanced Materials and Processes, October 1990,
P. 25. ASM International.
 Composite Molds
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(a) Schematic illustration of a semipermanent composite mold. Source: Steel

Castings Handbook, 5th ed. Steel Founders' Society of America, 1980. (b) A
composite mold used in casting an aluminum-alloy torque converter. This part was
previously cast in an all-plaster mold. Source: Metals Handbook, vol. 5, 8th ed.
 Vacuum-Casting (Counter-gravity low
pressure process
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Schematic illustration of the vacuum-casting process. Note that

the mold has a bottom gate. (a) Before and (b) after immersion of
the mold into the molten metal. Source: After R. Blackburn.
 Vacuum-Casting (Counter-gravity low
pressure process
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For thin-walled complex shape with

uniform properties
Example: gas turbine components from
superalloys, with 0.5mm wall thickness
Fine sand and urethane is molded over
metal dies and cured with amine vapor.
The mold is then immersed partially into
molten metal in induction furnace
The vacuum is about 2/3 of atmospheric
pressure.
 Pressure Casting
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The bottom-pressure casting process utilizes graphite molds for the production of steel
railroad wheels. Source: The Griffin Wheel Division of Amsted Industries Incorporated.
(b) Gravity-pouring method of casting a railroad wheel. Note that the pouring basin also
serves as a riser. Railroad wheels can also be manufactured by forging.
 Hot-Chamber Die-Casting
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Schematic illustration of the hot-chamber die-casting process.

 Hot-Chamber Die-Casting Machine
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800-ton hot-chamber die-casting machine, DAM 8005 (made in Germany in

1998). This is the largest hot-chamber machine in the world and costs about
$1.25 million.
 Cold-Chamber Die-Casting
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Schematic illustration of the cold-chamber die-casting process. These machines are

large compared to the size of the casting, because high forces are required to keep
the two halves of the dies closed under pressure.
 Die-casting processes
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Hot chamber Cold chamber

For low melting-point alloy: Zn, For high melting-point alloy: Al,
Mg, Sn and Pb Cu

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 Properties and Applications of Die-
Casting Alloys
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 Types of Cavities in Die-Casting Die
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Various types of cavities in a die-casting die. Source: Courtesy of American Die

Casting Institute.
 Centrifugal-Casting Process
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Schematic illustration of the centrifugal-casting process. Pipes,

cylinder liners, and similarly shaped parts can be cast with this
process. (b) Side view of the machine.
 Centrifugal Casting
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 Semicentrifugal Casting and Casting by
Centrifuging
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(a) Schematic illustration of the semi-centrifugal casting process. Wheels with

spokes can be cast by this process. (b) Schematic illustration of casting by
centrifuging. The molds are placed at the periphery of the machine, and the
molten metal is forced into the molds by centrifugal force.
 Squeeze-Casting
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Sequence of operations in the squeeze-casting process. This process combines

the advantages of casting and forging.
 Methods of Casting Turbine Blades
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(c)

Methods of casting turbine blades: (a) directional solidification; (b) method to

produce a single-crystal blade; and (c) a single-crystal blade with the constriction
portion still attached. Source: (a) and (b) After B. H. Kear, (c) Courtesy of ASM
International.
 Silicon Crystal Growing
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Two methods of crystal growing: (a) crystal

pulling (Czochralski process) and (b) the floating- (c) A single-crystal ingot
(c)
zone method. Crystal growing is important produced by the Czochralski
especially in the semiconductor industry. process. Source: Courtesy of
Intel Corp.
 Melt-Spinning
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(b)

(a) Schematic illustration of melt-spinning to produce thin strips of amorphous

metal. (b) Photograph of nickel-alloy production through melt-spinning. Source:
Siemens AG
 Types of Melting Furnaces
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Two types of melting furnaces used in foundries: (a) crucible, and (b) cupola.
FTMD - ITB