UNIT I

FOUNDRY TECHNOLOGY
Pattern and core making – moulding sand and testing -
green sand moulding – melting furnaces: cupola and
induction furnaces – special casting processes – shell,
investment, die casting, centrifugal castings principles of
gating system design - fettling and finishing of castings –
defects in casting.
 HISTORICAL DEVELOPMENT
• Earliest casting : high bronze statue
– Mohango daro Civilizaation -3000-3500 BC
• Harappan Civilization contained- Kiln (oven ) for melting , copper , gold
• Fine art , hand craft-idols of made by chola dynasty – of 9th century-
technology for making -intricate casting
• Casting tech transferred from India to middle east to Europe through
Portuguese in 14th century
• First cast iron tripot object weighing 270kg by Chinese technology-600BC
• Iron pillar in Delhi -QUTIPMINAR weighs 6 tones speaks about the
Casting Technology in the earliest Indian Civilization during Chandragupta
dynasty that dates back 5AD
• Colossal statue of Buddha – 1252AD in Jaipur speaks about Marvels of
Casting Technology existed in India

.
 MANUFACTRUING
• Manufacture is derived from two Latin words
• “MANUS” and “FACTUS”

HAND MADE

• Manufacturing is important
• Technologically
• Economically
• Historically
 TECHNOLOGY - Means
• Application of science to provide society those things
that are needed or desired
• Technology help to live better
• In the broadest sense it is a of converting raw material
into useful product

DEFINITION OF MANUFACTURINIG

INPUT CONVERSION OUTPUT

DR.V.S.SENTHIL KUMAR, ASSOCIATE PROFESSOR,DME,CEG,AUC-25.

MANUFACTURED PRODUCTS
• Consumer products
• Products purchase directly by consumers – Car, Tv, pc, Tennis
racket
• Capital goods
• Purchased by other companies/industries to purchase goods
and supplies – Machine tools, rail road equipment
 BASIC TYPES OF MANUFACTURING PROCESS

METAL
CASTING

METAL BASIC MANUFACTURING METAL

MACHINING PROCESS FORMING

FABRICATION
TECHNOLOGY
TYPICAL COMPONENTS MADE BY VARIOUS
MANUFACTURING

METAL MACHINING
METAL CASTING

METAL FORMING FABRICATION TECHNOLOGY

 METAL CASTING TECHNOLOGY
What is casting?
– Ability of fluid to assume the shape of container is exploited in
casting process which involve melting, pouring of molten
metal into mould and allowing to solidifying
– Solidified metal in casting or founding and hence name of
foundry
PATTERN

MELTING & POURING

OF METAL

MOULD

CASTING

.
TYPICAL CAST COMPONENTS
SEQUENCE OF MAKING CASTING
 Casting
It is the process of making metal parts, by pouring molten metal
into the cavity of the required shape and allowing it to solidify.

Refractory mold à pour liquid metal à solidify, remove à finish

 Cleaning

Machining
Why casting preferred?
v Size- Few grams to several ton
v Shape – Simple to complex
v Production Quantity – One number to multiple
v Accuracy – Close dimensional accuracy with special casting features
v Finish- Rough to fine
Major applications
v Transport- Automobile, aerospace, railways, shipping, space application
v Heavy Equipment – Farming, mining, construction
v Defence- vehicles, artillery
v Electrical machine- Motor casing, pump base, compressor
v Municipal castings- pipe fittings, manhole cover, sewage pipe, sanitary
fittings
v Home appliance- kitchen ware, furniture
v Handi craft- sculptures, jewelry , idols, lamp stand, decorative items.
REQUIREMENTS OF CASTING PROCESS
CASTING PROCESS
COMMON CAST METALS

METAL USAGE TYPICAL APPLICATION

Grey Iron 54% Engine Block, brake drum,
Machine tool bed, housing
Ductile Iron 20% Crank shaft, Camshaft, Valves,
brackets
Aluminium 12% Piston, Oil& fuel pump, Clutch,
housing, Carburetor
Steel 9% Machine parts, Gears
Copper base 2% Hydraulic Pump parts, Impellers

Zinc base 1% Handle, Grills, Toys

 ADVANTAGES & LIMITATIONS OF CASTINGS

ADVANTAGES LIMITATIONS
Intricate shape both external Poor finish of sand cast parts
internal can be cast on single
piece
Hollow & large parts be made Sand casting labour intensive

Any metals which can be melted Cast parts bulky & brittle
– Ferrous & Non Ferrous metal

Uniform cooling, better Some casting require machining

properties & damping capacity to get fine finish

No limitation of size, shape & Surface defects, porosity, cracks

product complexity on casting,
 Sand Casting
Various steps in the Sand casting are

• Placing a pattern having the shape of the desired casting in

sand to make an imprint
• Incorporating a gating system
• Filling the resulting cavity with molten metal
• Allowing the metal to cool until it solidifies
• Breaking away the sand mould
• Removing the casting
• Most sand casting operations use silica sand(sio2 ),which is
the product of the disintegration of rocks over extremely long
periods of time.
• Several factors are important in the selection of sand for molds
• The mold should have good collapsibility to avoid defects in
the casting
• The selection of sand involves certain tradeoffs with respect to
properties.
• Mulling machines are used to uniformly and thoroughly mull
sand with additives.
• Clay is used as a cohesive agent to bond sand particles,giving
the sand strength.
• Zircon, olivine and iron silicate sands are often used in steel
foundries for their low thermal expansion.
• Chromite is used for its high heat-transfer characteristics.
 Sequence of mould making

Sequence of Casting operation

CASTING PROCESS SEQUENCE
– PATTERN DEVELOPMENT
– MOULD PREPARTION
– MELTING & POURING
– FETLING & CLEANING
 Sand Mould
• Sand molds are characterized by the types of sand that
comprise them and by the methods used to produce them
• There are three basic types of sand molds
– Green-sand
– Cold-box
– No-bake molds

• The most common mold material is green molding sand,

which is a mixture of sand,clay and water.
• The term “green” refers to the fact that the sand in the mold is
moist or damp while the metal is being poured into it.
• Green-sand molding is the least expensive method of making
molds.
• Sand molds are also oven dried prior to pouring the molten
metal ,they are stronger than green –sand molds and impart
better dimensional accuracy and surface finish to the casting.

• However this method has draw backs they are

• Distortion of the mold is greater

• The castings are most susceptible to hot tearing because of the

lower collapsibility of the mold.

• The production rate is slower because of the drying time

required.
• The following are the major components of sand
molds
• Flask- mold is supported by a flask.
• Pouring Basin- into which molten metal is pored
• Sprue-molten metal flows downwards through this
• Runner systems
• Risers-addition metal to the castings
• Cores- inserts made from sand
• Vents-placed in molds to carry off gases produced.
PATTERN
v Pattern : It is the replica or facsimile of the product to be
made in respect of shape.
v Generally used in making Sand mould

PATTERN MATERIAL
vWood
vMetal
vPlastic
vWax
vThermocole
ADVANTAGES & LIMITATIONS OF DIFFERENT PATTERN MATERIALS

MATERIAL ADVANTAGES LIMITATIONS

Wood vLight weight & inexpensive vInherently non uniform structure

vGood workability vPoor wear & abrasive resistance
vEasy to repair vAbsorbs moisture tends to warp

Metal vMore durable & accurate vRelatively expensive than wood

vProvide smooth finish vNot easily repaired
vDo not deform on storage vHeavier than wooden pattern
vWear, abrasion, corrosion vFerrous metal gets rusted
resistance
Plastics vMore economical in cost vTends to bend on heavy
vHigh resistance to ramming force
corrosion vAdditional equipment is needed
vLighter than wood/metal
for making pattern
vMoulding sand stick less in
vDifficult to repair or rework
plastics than wood
vNo moisture absorption
strong & dimensionally stable
TYPES OF PATTERN
 PATTERN ALLOWANCE

• A duplicate of the product to be cast, modified dimensionally to reflect

process of material to be cast
• Modification incorporated in pattern are allowance or pattern allowance
• Expandable mould use some form of reasonable pattern
• Allowances are added to the pattern and mould cavity is larger than final
Casting.
 TYPES OF PURPOSE
ALLOWANCE
1.SHRINKAGE vTo compensate for volumetric contraction
ALLOWANCE during freezing of metal, this allowance is added
vShrinkage though volumetric, allowance
linearly expressed as % of mass or length
vPattern made larger applying shrink rule
depending metal / product
 TYPES OF ALLOWANCE PURPOSE

2. DRAFT ALLOWANCE vThe allowance which facilitate easy withdrawal

of pattern from mould walls
vSlight taper or draft is provided to vertical side
of mould walls all around
vDrat allowance is additive: 1 – 1.5 % of length
 TYPES OF PURPOSE Diagram
ALLOWANCE
3.MACHINING vTo remove rough surface exhibited in
ALLOWANCE casting especially sand casting by
subsequent machining
vAllowance is added to pattern to
provide compensation during machining
vDepends on finish requirement,
product complexity and type of material
to be cast

4.DISTORATION vThin section or abnormal change in

size of the product restrained in mould
which tend to distort upon cooling
vU or V shaped section tends to distort
more while cooling in mould
v1-2º is given as allowance inwardly
 TYPES OF PURPOSE
ALLOWANCE
5.SHAKE or vCavity enlarge while pattern is withdrawn
RAPPING due to tapping
vCavity made smaller. tapping of pattern
results original dimension – It is a subtractive
allowance
vAdded to parting surface or parallel to
parting surface

Size of the final pattern

MOULDING SAND
v Aggregate of sand (Moist) , clay and additives
Moulding Sand Consists of
1.Sand – Zirconium, olivine, chromites sand
2. Clay- bentonite, kalonite
3. Additives- organic additives
MOULDING SAND REQUIREMENTS
v Good refractiveness - Ability to with stand high temperature without
fusing or charing
v Good permeability- Ability of the sand to permit gases to escape
through sand mould. Hard ramming - poor permiabilty
v Chosiveness- (good bonding of grain size of silica – ability of mould
sand to retain the shape when packed into mould without crack
v Collapsibility- Ability of moulding sand to disintegrate from casting
easily . Improved by the addition of material like cellulose
v Strength- Retain the mould shape under molten metal pressure ( Hydro
stastic ) - Must resist penetration of molten metal into mould . –
(Green strength (Moist) ; Dry Strength)
Types of Moulding sand

v Green sand
v Dry sand
v Facing sand
v Loam sand
v Backing sand
v Parting sand
 Core
A core is a body made of refractory material
which is set in to the prepared mould before
closing and pouring it, for forming through holes,
recesses, projections and internal cavities.
1. Conventional Method
Ø Hand curing method
Ø Core blowing machine
Ø Extrusion machine
2. Hot core mould box method
3. Synthetic resin cold curing core sand method
4.Cold curing CO2 process
 MOULD & CORE ASSEMBLY

Purpose of core
v To produce hallow casting with the use of core/ core print
v Core outer size confirm inner size of the casting

CASTING CHAPLET
MOULD &
CORE
ASSEMBLY
MOULD SAND TESTING
Purpose:
v To ensure consistent quality of moulding sand in respect of their properties
TYPES OF TEST
v Grain size: Seiving dry sand downward through a set of parallel
standard seives of decreasing mesh size - Sand in weighed after seving .
Grain size is expressed in grain fines number.
v Moisture content: 50g sample sand specimen is heated to 100ºC and
difference in weight is estimated and expressed as % moisture.
v Clay constant: 50g moulding sand is washed with sodium hydroxide
solution. & weighed. Difference is expressed as percentage of clay.
v Permeability test: Standard test specimen placed in permeability meter
and flow of air is maintained. Pressure drop is determined. Pressure
drop indicate measure of permeability.
v Hardness strength: Using standard specimen of moulding sand in
Hardness tester , strength is evaluated in wet & dry stage to evaluate
green and dry strength
TYPES OF MOULDING PROCESS

Hand moulding
Machine moulding
1. Jolt machine
2. Jolt & square
3. Slinger
TYPES OF MOULDING PROCESS
Hand moulding
Machine Moulding
1. Jolt machine
2. Jolt & squeeze
3. Slinger
ADVANTAGES OF MACHINE MOULDING
v Offers high production rates in making mould
v Produces uniform and quality casting
v Lesser labour cost & less skilled labour can be employed
v Establishes most suitable gating system- runner , riser etc mounted on match
plate pattern itself
v Pattern offers longer life
v Lesser machining allowance are required
v Greater accuracy is secured in core assembly
LIMITATIONS
v Moulding large and complex and intricate shape are difficult
v Moulding Machine is not flexible as sand moulding
v Expensive equipment
v Not suitable for small production
 JOLT MACHINE and JOLT & SQUEEZE

ADVANTAGE
v Jolting offers better consolidation of moulding sand with uniform properties
v Higher production rate in making sand moulds
v Large size casting economically produce by this method
v Lesser cost of mould making
• LIMITATION
• Variation of sand density from bottom to top the moulding box
• Jolting produces noise pollution
• Doesn't ram properly at deep pocket and narrow places between vertical surfaces
JOLT & SQUEEZE MACHINE
 SAND SLINGER

• Sand slinger consists of impeller rotating at desire rotation speed.

• Moulding sand from the hopper is feed into the gravity
• Rotating Impeller throw the moulding sand downward into moulding cost
as contiously
• The Rotating impeller to the moulding sand create necessary force that fills
the moulding box with sand.
• Produces uniform density packing through out the mould
ADVANTAGES OF SAND SLINGER
v Mould filling and ramming are done at the same time
v Mould hardness can be controlled by regulating by impeller speed
v Delivers large quantity of sand that is suitable for ramming big moulds
v Irrespective of the size and shape of the mould , mould produce are of uniform
density.
v Total automation of sand handling can be done
LIMITATIONS
v Expensive equipment
v Skilled operator to regulate the machine
v Not suitable for small volume production
MELTING PRACTICES

• Melting is an equally important parameter for obtaining a quality castings.

• A number of furnaces can be used for melting the metal, to be used, to
make a metal casting.
• The choice of furnace depends on the type of metal to be melted.
TYPES OF FURNACES
• Crucible furnaces
• Cupola
• Induction furnace
• Reverberatory furnace
CRUCIBLE FURNACE

• Small capacity furnace typically used for small melting

applications.

• Suitable for the batch type intermittent production.

• The metal is placed in a crucible which is made of clay and

graphite.

• The energy is applied indirectly to the metal by heating the

crucible by fuel like coke, oil or gas.
COKE FIRED CRUCIBLE
FURNACE
 CUPOLA
• Tall, cylindrical furnace used to melt iron and
ferrous alloys.
• Alternating layers of metal and ferrous alloys,
coke, and limestone are fed into the furnace
from the top.
• Cupola is lined with refractory bricks
• The molten metal flows out of a spout at the
bottom of the cupola. .
SCHEMATIC DIAGRAM OF CUPOLA
 DESCRIPTION OF CUPOLA
• The cupola consists of a vertical cylindrical steel sheet and lined inside with
acid refractory bricks.
• The lining is generally thicker in the lower portion of the cupola as the
temperature are higher than in upper portion
• There is a charging door through which coke, pig iron, steel scrap and flux
is charged
• The air blast is blown through the tuyeres
• These tuyeres are arranged in one or more row around the periphery of
cupola
• Hot gases which ascends from the bottom (combustion zone) preheats the
iron in the preheating zone
• Cupolas are provided with a drop bottom door through which waste
materials consisting of coke, slag etc. can be taken out after melt
• A slag hole is provided to remove the slag from the melt
• Through the tap hole molten metal is poured into the ladle
• At the top conical cap called the spark arrest is provided to prevent the spark
emerging to outside
• C + O2 CO2 + Heat
• 2Mn + O2 MnO2 + Heat
• Si+ O2 SiO2 + Heat
• 3Fe + 2CO Fe3C + CO2
 Melting Furnaces
Electric furnace
Charge is melted by heat generated from an electric arc
Induction furnace
Uses an alternating magnetic field to heat the metal
ADVANTAGES OF CUPOLA

v Simple design and easier construction

v Low initial cost as compared to other furnaces of same capacity

v Simple to operate and maintain in good condition

v Economy in operation and maintenance

v Less floor space requirements as compared to those of other furnaces of

capacity

v Cupola can be continuously operated for many hours.

LIMITATIONS

v Close temperature is difficult to maintain.

v Since molten iron and coke come in contact with each other, certain
elements (like Si, Mn) are lost which others (like sulphur) are picked
up. This changes analysis of molten iron.
RUNNER
v Ingate for feeding molten metal into cavity
v Suitably designed to admit the metal easily & permit filling of mould
cavity
v For large size casting , more ingate may be provided

RISER
v Passage through which metal rises to ensure the molten metal in filled
fully
v Provides feeder head to compensate for shrink

PURPOSE
v To feed the molten metal to solidifying casting so that shrink cavities
are avoid
v To ensure proper mould filling
v To permit gas, vapour to scrange to atmosphere
Special Casting Processes
Types:
• Gravity / Permanent mold casting
• Die casting
– Low pressure die casting
– High pressure die casting
• Hot chamber
• Cold chamber
• Centrifugal casting
– True centrifugal casting
– Semi centrifugal casting
– Centrifuge casting
• Shell molding
• Investment casting
• CO2 process
 Shell Moulding
Casting process in which the mold is a thin shell of sand held
together by thermosetting resin binder

Figure 11.5 Steps in shell-molding: (1) a match-plate or cope-and-drag metal pattern is

heated and placed over a box containing sand mixed with thermosetting resin.
 Shell Moulding
Figure 11.5 Steps in shell-molding: (2) box is inverted so that sand and resin
fall onto the hot pattern, causing a layer of the mixture to partially cure on
the surface to form a hard shell; (3) box is repositioned so that loose
uncured particles drop away;
 Shell Moulding

Figure 11.5 Steps in shell-molding: (4) sand shell is heated in oven for several
minutes to complete curing; (5) shell mold is stripped from the pattern;
 Shell Moulding

Figure 11.5 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.
Advantages and Disadvantages
— Advantages of shell molding:
— Smoother cavity surface permits easier flow of molten
metal and better surface finish
— Good dimensional accuracy - machining often not
required
— Mold collapsibility minimizes cracks in casting
— Can be mechanized for mass production
— Disadvantages:
— More expensive metal pattern
— Difficult to justify for small quantities
 Ceramic Mould Casting
Uses a mold made of refractory ceramic materials
which can be used for high-temperature applications
Ceramic Mould Casting
 Ceramic Mould Casting
Advantages:
Intricate detail, close tolerances, smooth finish

Limitations:
Mold material is expensive and not reusable

Common metals:
Ferrous and high-temperature nonferrous metals are
most common; can be used with alloys of aluminum,
copper, magnesium, titanium and zinc
Investment casting (lost wax casting)
(b) Multiple patterns
(a) Wax pattern
assembled to wax
(injection molding)
sprue

(c) Shell built à

(d) dry ceramic immerse into ceramic
melt out the wax slurry
fire ceramic (burn à immerse into fine sand
wax) (few layers)

(e) Pour molten metal (gravity)

à cool, solidify (f) Break ceramic shell
[Hollow casting: (vibration or water
pouring excess metal before blasting)
solidification

(g) Cut off parts

(high-speed friction
saw)
à finishing (polish)
 Investment Casting

Figure 11.8 Steps in investment casting: (3) the pattern tree is coated with a
thin layer of refractory material, (4) the full mold is formed by covering
the coated tree with sufficient refractory material to make it rigid
 Investment Casting

Figure 11.8 Steps in investment casting: (5) the mold is held in an inverted
position and heated to melt the wax and permit it to drip out of the cavity,
(6) the mold is preheated to a high temperature, the molten metal is
poured, and it solidifies
 Investment Casting

Figure 11.8 Steps in investment casting: (7) the mold is broken

away from the finished casting and the parts are separated
from the sprue
 Investment Casting

Figure 11 9 A one-piece compressor stator with 108 separate airfoils made by

investment casting (photo courtesy of Howmet Corp.).
 Advantages and Disadvantages
• Advantages of investment casting:
– Parts of great complexity and intricacy can be cast
– Close dimensional control and good surface finish
– Wax can usually be recovered for reuse
– Additional machining is not normally
required - this is a net shape process
• Disadvantages
– Many processing steps are required
– Relatively expensive process
 Die Casting

A permanent mold casting process in which

molten metal is injected into mold cavity under
high pressure
• Pressure is maintained during solidification,
then mold is opened and part is removed
• Molds in this casting operation are called dies;
hence the name die casting
• Use of high pressure to force metal into die
cavity is what distinguishes this from other
permanent mold processes
 Die Casting Machines

Designed to hold and accurately close two

mold halves and keep them closed while
liquid metal is forced into cavity
• Two main types:
1. Hot-chamber machine
2. Cold-chamber machine
 Hot-Chamber Die 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
• Applications limited to low melting-point
metals that do not chemically attack plunger
and other mechanical components
• Casting metals: zinc, tin, lead, and magnesium
 Hot-Chamber Die Casting

Figure 11.13 Cycle in hot-chamber casting: (1) with die closed

and plunger withdrawn, molten metal flows into the chamber
Hot-Chamber Die Casting

Figure 11.13 Cycle in hot-chamber casting: (2) plunger

forces metal in chamber to flow into die, maintaining
pressure during cooling and solidification.
Cold-Chamber Die Casting Machine
Molten metal is poured into unheated chamber
from external melting container, and a piston
injects metal under high pressure into die
cavity
• High production but not usually as fast as
hot-chamber machines because of pouring
step
• Casting metals: aluminum, brass, and
magnesium alloys
• Advantages of hot-chamber process favor its
use on low melting-point alloys (zinc, tin,
lead)
Cold-Chamber Die Casting

Figure 11.14 Cycle in cold-chamber casting: (1) with die

closed and ram withdrawn, molten metal is poured into
the chamber
 Cold-Chamber Die Casting

Figure 11.14 Cycle in cold-chamber casting: (2) ram forces metal to

flow into die, maintaining pressure during cooling and solidification.
 Advantages and Limitations

Advantages
– Economical for large production quantities
– Good accuracy and surface finish
– Thin sections are possible
– Rapid cooling provides small grain size and
good strength to casting
Disadvantages
– Generally limited to metals with low metal
points
– Part geometry must allow removal from die
 CO2 Process

Ø Basically a hardening process

Ø CO2 passed through the sand mix containing
sodium silicate, the sand becomes strong by
sodium silicate gel

Na2O, (x)SiO2 + (x)H2O + CO2

Na2CO3 + SiO2.
(x)H2O
Comparison of Casting Processes
 Cleaning and Finishing
1. Casting is taken out of the mould by shaking and the Moulding
sand is recycled often with suitable additions.
2. The remaining sand, some of which may be embedded in the
casting, is removed by means of Shot blasting.
3. The excess material in the form of sprue, runners, gates etc.,
along with the flashes formed due to flow of molten metal into
the gaps is broken manually in case of brittle casting or
removed by sawing and grinding in case of ductile grinding.
4. The entire casting is then cleaned by either shot blasting or
chemical pickling.
5. Sometimes castings are heat treated to achieve better
mechanical properties.
DIE CASTING

Gravity die casting or permanent mould casting

FEATURES
v Uses preshaped cavity called dies
v Dies are split type with runner, riser, gates to feed metal
v Split dies enables easy extraction of casting from dies
v Dies made of cast iron
v Metal dies are better heat conditions & faster rate of cooling
v Metal mould resist high temp & can be used repeatedly

METAL SUITABLE
v Aluminium alloys, copper alloys, magnesium & low melting point
methods
Typical parts made
v Automobile piston, cylinder heads, gear blank for appliance and
kitchen ware
 ADVANTAGES LIMITATION
1. Good surface finish, close dimensional 1. Metal dies are expensive
tolerance

2. Better mechanical properties 2. Not economical for low production runs

3. High production rate 3. Intricate shapes cannot be cast

 HOT CHAMBER DIE CASTING & COLD CHAMBER DIE CASTING

HOT CHAMBER METHOD COLD CHAMBER METHOD

Melting furnace integral part of machine Melting furnace in away from die
casting machine

Metered quantity of melt is injected by a plunger Required melt quantity is ladled to

machine and pushed to die cavity

Generally suited low melting non ferrous metals Metals used in non ferrous with
relatively high melting point

Faster production cycle Low volume production

ADVANTAGES OF PRESSURE DIE CASTING

vUsed for mass production resulting low unit cost

vThin and dense structure of metals with finer details as the

solidification is under external pressure

vExtremely fine finishes can be obtained elementary subsequent

machining operation

vComponents can be produced to very close dimensional tolerance

and with precise reproduction

vDie casting operations permit automation of the process

vMechanical properties are usually superior to sand cavity

vMore economic use of metal- minimum waste

vInserts can be incorporated

DIE CASTING
Gravity die casting or permanent mould casting
PERMANENT MOLD CASTING AND TYPICAL
PRODUCTS
 INVESTMENT
CASTING AND TYPICAL PRODUCTS
COLD CHAMBER DIE CASTING AND TYPICAL
PRODUCTS
v The major function of the gating system is to deliver clean metal into the
mold cavity without deteriorating the quality of the metal. This includes
items such as:
1. Avoiding the passage of slag or dross into the casting
2. Avoiding the production of dross during passage through the gating
3. system into the casting
4. Minimizing the entrainment of air or mold gases into the metal
5. stream
6. Avoiding mold and core erosion
7. Introducing metal at a rate to minimize shrinkage and distortion

v Secondary considerations include:

1. Ease of molding of the gating system
2. Ease of removal of the gating system from the casting
3. Improvement of the casting yield
 Centrifugal Casting
A family of casting processes in which the
mould is rotated at high speed so centrifugal
force distributes molten metal to outer regions
of die cavity
• The group includes:
– True centrifugal casting
– Semicentrifugal casting
– Centrifuge casting
 True Centrifugal Casting
Molten metal is poured into rotating mold to
produce a tubular part
• In some operations, mold rotation commences
after pouring rather than before
• Parts: pipes, tubes, bushings, and rings
• Outside shape of casting can be round,
octagonal, hexagonal, etc , but inside shape is
(theoretically) perfectly round, due to radially
symmetric forces
 True Centrifugal Casting
Figure 11.15 Setup for true centrifugal casting.
 Semicentrifugal Casting
Centrifugal force is used to produce solid
castings rather than tubular parts
• Molds are designed with risers at center to
supply feed metal
• Density of metal in final casting is greater in
outer sections than at center of rotation
• Often used on parts in which center of casting
is machined away, thus eliminating the portion
where quality is lowest
• Examples: wheels and pulleys
Semicentrifugal Casting
 Centrifuge Casting

Mold is designed with part cavities located

away from axis of rotation, so that molten
metal poured into mold is distributed to these
cavities by centrifugal force
• Used for smaller parts
• Radial symmetry of part is not required as in
other centrifugal casting methods
Centrifuge Casting
 Vacuum casting
Similar to investment casting, except: fill mold by reverse gravity

Easier to make hollow casting: early pour out

ADVANTAGE OF MACHINE MOULDING
v Uniform and device packing of sand
v Finer and interactive details with good mould cavity
v Better finish and faster mould making cycle
v Good reproducability of pattern details
GATING SYTEM
Importance
A good gating system conveys the material and deliver to all sections of mould cavity
Rate of metal movement controlled by gating system
Shape, size, length of gates influenced in controlling temp loss
Metal loss is mix with proper gating system
Fuction
To ensure proper filling of mould cavity
To promote proper dimensional solidification
Provide means for separation of non-metallic inclusions
To regulate the rate of metal flow in cavity
To feed the metal during shrinkage
To minimise turbulance in metal flow
To prevent sand particles entering the cavity
GATING SYTEM

IMPORTANCE
v A good gating system conveys the material and deliver to all sections
of mould cavity
v Rate of metal movement controlled by gating system
v Shape, size, length of gates influenced in controlling temp loss
v Metal loss is mix with proper gating system
FUCTION
v To ensure proper filling of mould cavity
v To promote proper dimensional solidification
v Provide means for separation of non-metallic inclusions
v To regulate the rate of metal flow in cavity
v To feed the metal during shrinkage
v To minimise turbulance in metal flow
v To prevent sand particles entering the cavity
GATING AND RISERING FOR SIMPLE PLATE
CASTING.
 CASTING DEFECTS
• Any unwanted deviation from the desired requirements
in a cast product results in a defect.
• Some defects in the cast products are tolerable while
others can be rectified.
MAJOR DEFECTS IN SAND CASTINGS:
• 1. Gas defects
• 2. Shrinkage cavities
• 3. Moulding material defects
• 4. Pouring metal defects
• 5. Metallurgical defects
CASTING DEFECTS
TYPE OF CAUSES REMIDAL REMARKS SKETCH
DEFECT
Blow vSpherical / vProper moisture
holes flattened cavities control in sand mould
present inside or vImprove venting
surface of casting systems
caused due to vMould hardness
entrapment of gas-
void space
Pin hole vCaused due to vControlling the
porosity dissolved H2 gas, in pouring temp
molten metal when vUse of additives while
metal gets solidified, pouring
expels the gas leaving
long, small diameter
holes
Shrinkage vVolumetric vAllowance to be
contraction of metal verified
vInsufficient
allowance
CASTING DEFECTS
TYPE CAUSES REMIDAL SKETCH
OF REMARKS
DEFECT

Hot tear vExternal cracks vFillet & rounding Hot tear

causing tearing due to corner, design of
thermal stress. modification
v Abrupt change in
section of casting
Could vDifferential rate of vImprove runner &
shut flow cooling gate design
vLack of complete
fusion of metal

Rat tail vPenetration of vProper ramming

molten metal into
mould walls

Scab vRough, thin layer of

metal protruding
above cast surface
CASTING DEFECTS

TYPE CAUSES REMIDAL SKETCH

OF REMARKS
DEFEC
T
Mould vDue to misalignment vCheck the
shift of cope and drag alignment of the cope
vShift of the mould and drag
while pouring molten vCheck the axis of
metal the mould cavity in
cope and drag and
the axis must be
aligned correctly

Misrun vMetal start freezing vImprove runner &

before reaching the gate design
farthest point of the vCheck the fluidity
mould cavity due to of the metal
insufficient superheat
 GAS DEFECTS
• These defects are due to lower gas passing tendency of the
mould.
vCaused due to lower venting , lower permeability of the
mould and improper design of the casting.
vThe lower permeability of the mould is due to use of
finer size grains of sand, higher percentage of clay &
moisture and excessive ramming of the mould.
vPin hole porosity: As the molten metal gets solidified
it loses the temperature which decreases the solubility of
gases and thereby expelling the dissolved gases.

Various Gas Defects

 Moulding Material Defects
• These defects are originated due to some specific characteristics of the
moulding materials like insufficient strength, improper ramming etc.
The various defects under this category are discussed in detail.
v Cuts and Washes: These appear as rough spots and areas of excess
metal and are caused by the erosion of the moulding sand by the
flowing molten metal. This may be due to insufficient strength of
mould material or the high velocity of the molten metal.
Remedies
• The proper choice of moulding sand
• appropriate moulding method
• Improve the design of gating
• To reduces turbulence
• Provide multiple ingates.
 Moulding Material Defects
vMetal Penetration: When molten metal enters
the gaps between the sand grains, the result
would be a rough casting surface.
ØCaused due to use of coarse sand grains in mould
material.
ØCaused due to higher pouring temperature.
Remedies
vChoosing appropriate grain size of sand with proper mould wash
Moulding materials Defects
 Moulding Material Defects
v Fusion: Fusion of sand grains with molten metal.
vCaused due to lower refractoriness of the binder.
vvery high pouring temperature.
Remedies
v The choice of an appropriate type and amount of binder(Bentonite)
v Run out: Caused due to leak of molten metal in the sand mould.
Remedies
v Verify the mould design and alignment
v Buckles: Long, broad, vee-shaped depression occurring on the surface
of a flat casting.
v Mould expansion due to high temperature
Remedies
v Verify the mould design with proper venting
v Proper testing of moulding sand
 Moulding Material Defects
vRat tail: Long shallow angular depression normally
found in a thin casting.
vCaused due to compression of moulding sand.
Remedies
v Check the constancy and properties of moulding sand
vScab: Thin layer of a metal, protruding above the
casting surface.
vDue to removal of the moulding sand due to flow of the
mould cavity.
vSand erosion
Remedies
v Verify the properties of the moulding sand
v Check the gating design
 Moulding Material Defects
v Swell:
v Under the influence of metallostatic forces, the mould wall may move
back causing a swell in the dimensions of the casting.
v Caused due to improper ramming of the mould.
v Drop:
v An irregularly shaped projection on the cope surface of a
casting is called a drop.
v Caused due to dropping of sand from the cope or other
overhanging projections into the mould.
Remedies
v Adequate strength and hardness of the moulding sand
v Provide gaggers if necessary.
 Other Defects
• Mould and Core shift: A misalignment
between two halves of a mould or of a core
may give rise to a defective casting
 Pouring Metal Defects
v Misrun:
v Metal start freezing before reaching the farthest point of the mould cavity due
to insufficient superheat.
v Cold shut:
v Caused due to non fusion of two streams of metal resulting in a discontinuity
or weak spot in casting.
Remedies
v Due to lower fluidity of the molten metal or small thickness of the casting.
v The fluidity of the metal can be improved by changing the composition of
molten metal or raising the pouring temperature.
v The surface area to volume ratio of the mould can be reduced.
v Improve the venting to minize the back pressure in the mould cavity
Pictorial Representation of Defects
 Metallurgical Defects
• Hot tears:
v Caused due to differential rate of cooling causing rupture in the
casting when its hot
Remedies
v Improve the casting design
v Hard spots: Caused by chilling of the casting excessively at
particular spot.
 Causes of Blow Holes
Blow Holes Defect Causes

Blow Blow holes and Open blows:

Holes These are spherical, flattened or
elongated cavities present inside
the casting or on the surface. When
present inside the casting it is
called blow hole while it is termed
as open blow if it appears on the
surface of the casting. These
defects are caused by the moisture
left in the mould and the core. Due
to heat of the molten metal the
moisture is converted into steam,
part of which when entrapped in
the casting ends up as blow hole or
ends up as open blow when it
reaches the surface. Thus in green
sand mould it is very difficult to
get rid of the blow holes, unless
properly vented.
Casting Defects
Casting Defects
Casting Defects
Casting Defects
Casting Defects
 Inspection Methods

v Visual inspection
v Dimensional Inspection
v Mechanical testing
v Flaw detection by NDT
v Metallurgical inspection
White light inspection, pressure test, magnetic particle inspection,
radiographic test, ultrasonic inspection etc. are used