Two Major Classification of Casting Process

Expandable Molding Processes Permanent Molding Processes

 Expandable Molding Processes
❑Sand casting

❑Shell molding

❑ Vacum Molding

❑ Plaster molding alçı kalıp

❑ Expanded Polystrene Molding

❑ Investment Casting hassas kalıp

 SHELL MOLDING
This process, mould is a thin shell. This is made of sand held together by thermosetting
resin binder
Heated metal
Model

Sand with resin Box

binder

Steps: (1) A Metal pattern is heated and placed over a box containing sand mixed with
thermosetting resin
 SHELL MOLDING STEPS
The box is inverted so that sand and resin
mixture fall on the hot pattern, causing a
layer of the mixture to cure on the
pattern surface to form a hard shell
The box is positioned to the previous
stage, so that loose uncured particles
drop away

kum ve reçine karışımı ısı ile kalıbın şeklini alıyor

 SHELL MOLDING STEPS
Sand shell is heated in oven for several The shell mold is removed
Minutes to complete curing from the pattern
 SHELL MOLDING STEPS
Two halves of the shell mold are assembled, supported by sand or
metal shot in a box and pouiring is completed
VACUUM MOULDING
 PLASTER MOLD CASTING
❑ Similar to sand casting method.

❑ Metal mold is used.

❑ The mold is made of plaster of Paris with the addition of talc and silica flour

to improve strength and to control the time required for the plaster to set.

❑ Permeability is low. This problem is solved by using a special mold

composition [50 % of sand is mixed with the plaster]

❑ Used only for Al, Mg, Cu based alloys

 PLASTER MOLD CASTING
Advantages
• High accuracy and surface quality

• Smooth surfaces could be obtained

Disadvantages
Moisture must be removed
Plaster can not resist high temperatures. Therefore low melting moint
alloys could be casted.
INVESTMENT CASTING
Stator from investment casting
INVESTMENT CASTING
 PERMANENT-MOLD CASTING PROCESSES
❑In these processes, molds are used repeatedly and the casting part can be

easily removed

❑Molds are generally made of steel

❑ Materials that can be cast: Al, Mg, Cu based alloys

❑ Advantages: good surface finish, dimension tolerance

❑ Limitations: restricted to simple part geometries, low melting point metals

 PERMANENT-MOLD CASTING PROCESSES

❑ Permanent (hard-mold) Mold Casting sabit kalım döküm

❑ Die Casting basınçlı döküm

❑ Centrifugal Casting santrifüj döküm

 PERMANENT MOLD (HARD MOLD) CASTING PROCESS
❑ The mold cavity and gating system are machined into the mold and thus
become an integral part

❑ Core mades of metal or sand aggregate are plasced in the mold prior to
casting

❑ In order to increase the life of permanent molds, the surfaces of the mold
cavity are coated with a refractory slurry or sprayed with graphite every few
castings.

❑ This process is used mostly for aluminum, magnesium, copper alloys and gray
iron because of their generally lower melting points.
 THE STEPS IN PERMANENT MOLD PROCESS

❑ The mold are preheated (150𝐶 0 − 200𝐶 0 ) to facilitate metal flow

❑ The molds are coated or sprayed to aid heat dissipation and separate of the product

❑ The molds are clamped together by hydraulic cylinder

 THE STEPS IN PERMANENT MOLD PROCESS

❑ The molten metal is the poured through the gating system

❑ After solidification, the molds are opened and the part is removed
ADVANTAGES AND DISADVANTAGES OF PERMANENT MOLD
PROCESS
❑ This process is used mostly for aluminum, magnesium, copper alloys and gray iron because of their generally
lower melting points

Advantages:

❑ This process produces at high production rates.

❑ Parts have good surface finish, close dimension tolerances

❑ Parts are uniform and good mechanical properties.

Disadvantages:

❑ Not economical for small products

❑ Intricate shapes cannot be cast by this process.

❑ Equipment costs can be high due to die and labor costs

 DIE CASTING PROCESS
❑ In this process, the molten metal is forced into th die cavity at high pressures from 7 to 350
MPa.
❑ This process is divided into two groups:
a) Hot chamber process
b) Cold chamber process
Hot Chamber Process:
❑ Molten metal is melted in a container attached to the machine, an d a piston is used to
pressurize metal under high pressure into the die. Typical injection pressures are between 7
and 35 MPa.
 HOT-CHAMBER PROCESS IN DIE CASTING
❑ Production rate of 500 parts/hour are common
❑ Injection system is submerged into the molten metal and hence pose problem
of chemical attack on the machine components.
❑ Low melting point alloys such as zinc, magnesium and lead are commonly use in
this process
 COLD CHAMBER PROCESS IN DIE CASTING
❑ Molten metal is poured from an external container into the mold cavity and
piston is used to inject the molten metal into the die cavity.
❑ Injection pressure: 14 to 140MPa.
❑ Although it is a high production process, it is not as fast as hot chamber
machines.
 COLD CHAMBER PROCESS
❑ High-melting point alloys of aluminum, magnesium and copper are normally
cast using this method

❑ The machines may be horizantal or vertical

 ADVANTAGES AND DISADVANTAGES OF DIE CASTING
PROCESS
Advantages
❑ High production rates and economical
❑ Close tolerances possible of the order of 0.076 mm
❑ Thin section with 0.5 mm can be made
❑ Small grain size and good strength casting can be because of rapid cooling

Disadvantages
❑ Equipment costs are high
❑ The dimensions of the manufactured part are limited in this process
 CENTRIFUGAL CASTING
❑ In this method, the mold is rotated at high speed so that the molten metal is

distributed by the centrifugal force to the outer regions of the die cavity

❑ It consists of three groups:

a) True centrifugal casting

b) Semicentrifugal casting

c) Centrifuging
 TRUE CENTRIFUGAL CASTING
❑ Molten metal is poured into a horizontal rotating mold at one end.

❑ The high speed rotation results in centrifugal forces that cause the metal to
take the shape of the mold cavity.
❑ The outside shape of the casting can be non-round, but inside shape of the
casting is perfectly round.
❑ Pipes, gun barrels, tubes, rings and bushings are manufactured by this process
SEMICENTRIFUGAL CASTING
 CENTRIFUGING
• In centrifuging, mold cavities of any shape are placed at a certain distance
from the axis of rotation. The molten metal is poured from the center and is
forced into the mold by centrifugal forces.