Casting of Metals

Principles and Classification

Solidification Process and Time
Mold and Pattern Design
Basic Principle
A cavity with a shape that bears some
resemblance to the desired part is cut
into a mold. A metal is heated to a
temperature above the melting point
and the molten metal is poured into
the cavity. The molten metal solidifies
and it is removed from the mold and
allowed to cool down.
Classification of Solidification Process

Permanent
Pattern
Expendable
Pattern

Molding
Sand Molding Preparation
Sand Molding Preparation Cont’d
 Sand Molding Preparation Cont’d

Core  Hot molten metal flows around it to creates internal geometry

Made of sand and industrial sugar. Converted to brittle material
which easily broken up and removed.
Parts of Sand Mold
Sand Molding with Molten Part

Solidified Cast
Part
 Parts of a Sand Mold

(a) Open Mold (b) Closed Mold

vent

Gate
Foundry Terminology
 Cope  Vent
 Drag  Riser (Reservior)
 Pattern  Parting Line
 Core  Flask
 Sprue  Green Sand
 Runner  Dry Sand
 Gate  Cheek
 Pouring Basin
 Technical Issues in Casting

A. Heating / Pouring / Solidification

Solid : Heat / Energy Required

Liquid : Pouring Temperature (Degree of Superheat)

Molding : Sprue Design

Pouring : Pouring Rate, Mold Fill Time

Solidification : Solidification Time, Riser Design

B. Process Selection
(i) Performance Index / Rating
(ii) Cost per Part Analysis
 Heat Required

a. Solid (Room Temperature) Solid (Melting Point)

Heat , H s  Mass  Specific Heat  Temperatur e Change

H s  mc s  T

Temp H s  mc s T m  T 0 
Tp
L

Tm S+L

S
To

Time
 Heat Required Continued

b. Solid (Melting Point) Liquid (Melting Point)

L+S
Tm Latent Heat , H f
 mh f

hf Latent heat of Fusion per unit mass.

Tp c. Liquid (Melting Point) Liquid (Pouring Temp.)

Tm H l  mc l  T

H l  mc l T p  T m 
d. Total Heat Required (H)
H  Hs  H f
 Hl

note : mass , m    V
Example 1- Heating
 Note: 1 cal = 4.2 J

Solution
t Disc, D = 40 cm Thickness, t = 5 cm
Pure Aluminum; Latent heat, hf = 389.3 J/kg
D Specific Heat, Cs = 0.21 Cal/g-oC
Cl = 0.21 Cal/g-oC
Density ρ = 2.70 g/cm3
Temperatures: To = 25 C Tm = 660 C Tp = 800 C

Volume of Casting, V = (πD2/4)t = (π*402/2)*5 = 6283 cm3

Heated Volume, VH = 1.05V = 6597 cm3

Heated Mass, m = ρV = 2.70 x 6597 = 17,812 g

Heat Required = Ht(To to Tm) + Ht(Fusion) + Ht(Tm to Tp)

= mCs(Tm – T0) + mhf + mCl(Tp – Tm)
= 9.95 MJ + 6.93 MJ + 2.19 MJ
= 19.07 MJ
 Pouring (Sprue Design)
Pouring Basin

Near Top
Sprue Diameter, d1

Diameter Velocity, V1
Height, h

Bottom
Diameter, d2
Velocity, V2

Let Q = Pour Rate (volume/unit time) or (in3/sec or liter/s)

Q = Flow Area * Velocity
Q = A*V
Near Top, Q = A1V1 Bottom, Q = A2V2
 Sprue Diameters

Design Concept: To avoid gas entrapment or Aspiration

FLOW Continuity  constant flow rate

A1V 1  A 2V 2
d1 d 2
2 2

V1  V2
d V1  d V 2
2 2
4 4 1 2

V1
d2   d1 NOTE: V2 > V1 so d2 < d1
V2
Thus diameter decreases from top to bottom
Sprue Height

At 1, Total Energy, E1
1
E 1  PE  KE
1
E 1  mgh 
2
mv 1
Height 2
(h)
v1  0 (pouring) – In the basin

2
Thus E 1  mgh
1
At bottom E 2  mgh  mv
2
2
h 0
2
1
E2 
2
mv 2
2
 Conservation of Energy

E1  E 2
1
mgh 
2
mv 2
2

v2  2 gh h can be calculated if ν2
is known
Desired Area at Base of Sprue

Q Q
Ab  OR Ab 
V2 2 gh
 Desired Sprue Height for a given
Flow Rate

2
1  Q 
h  
 
2 g  Ab 

Mold Fill Time (MFT)

Volume Poured
MFT 
Q
Example – Flow Analysis
Example – Sprue Design
Shrinkage During Solidification and Cooling

(close to 5%)
Shrinkage During Solidification and Cooling Cont’d
Example - Shrinkage
Example - Shrinkage
Example - Shrinkage
Solidification Curve – Pure Metal
Solidification Curve for Alloys
 Total Solidification Time (TST)

Chvorinov’s Rule n
V 
Total Solidification Time, TST, TST  C m  
Where V = Volume of Casting
 A
A = Surface Area of Casting exposed to Mold and Cores

n = exponent ( n =2 for expendable mold castings)

n = 1 for permanent mold castings

V/A = Casting Modulus

Cm = Mold Constant. This is a function of Mold Material and Cast Material

Mold Material: Specific Heat, Thermal Conductivity, Density

Cast Material: Heat of Fusion, Density, Melting Temperature, Thermal

Conductivity
 Examples of Casting Modulus (V/A)

1. Cube
A  6a
2
V  a
3
a
V a
Modulus , 
a
A 6
a

2. Sphere 4
A  4 a
2
V  a
3
a
3
V a
Modulus , 
A 3
3. Solid Cylinder / Disk

V  r h
2

A  2 rh  2  r 
h
2

4. Hollow Cylinder / Disk

V   r   r h
r1 r2
2 2
2 1
h
A = Exposed Area

A  2 r2 h  2 r1 h  2 r2  r1 
2 2
5. Modulus of Composite Shapes

(a)
r

r1 r2
h

t h

w (b)
t
b

b
 Riser Design

Concept: Riser should be last section to solidify

Steps
1. Calculate TST for the Casting
2. Decide on TST for Riser such that TST riser  TST casting
3. Determine Riser Modulus
2
V 
TST riser  Cm  
 A  riser
1

V   TST 2
Solve     

 A  riser  Cm 
 Cylindrical Riser

Modulus
 D
  2

4

h 
  TST
 
1

2

D

of Solid  
2  
  Dh  D   Cm 
Cylinder:  4  riser
h

Determine D/h ratio.

 Put D in terms of h, solve for h
OR
 Using D/h ratio and knowing h,
solve for D
Spherical Riser
1

a  TST 2
a   
3  C 
 m 
Examples – Solidification Time
Examples - Riser Design
 Pattern Allowances

Pattern: A replica of the part to be cast and is used to prepare the mold.
It is made either of wood or metal. Metals: Al, Mg, commonly used.

It is made somewhat larger than the final part for various reasons.

This excess in dimensions is referred to as “pattern allowance”.

Shrink Rule: A special ruler with the expansion added to the dimensions

Regular Rule – 1 ft

Shrink Rule
Major Pattern Allowances
1. Shrinkage Allowance:
A linear allowance added to the dimensions to compensate for
contractions of the casting.

Liquid Solid (Freezing Solid (Room Temp)

Temp)

Desired Part
Major Pattern Allowances
2. Machining Allowance:
An allowance added to the dimensions so that we may later
machine it off to produce better surface finish and tolerance.
 Major Pattern Allowances
3. Draft Allowance: An angular allowance placed on the pattern to
facilitate its removal from the mold.

4. Distortion Allowance: Needed for thin irregular sections.