BASIC ENGINEERING MATERIAL

INTRODUCTION Technological properties are those qualities which give information regarding the
suitability of metals for various technological operations or processes. Such properties are highly
desirable in shaping, forming and fabrication of materials.

The technological properties that we will be focusing on is casting and rolling ability of the materials.
We will be discussing about the definition of each abilities, the process and application of each
abilities and some examples of each abilities.

Casting

Casting is a process in which a liquid metal is poured into a mould that contains a hollow shape of
the intended shape. The metal is poured into the mould through a hollow channel called a sprue.
The metal and mould are then cooled, and the metal part (the casting) is extracted.

There are many different metal casting processes used in the manufacture of parts. Two main
branches of methods can be distinguished by the basic nature of the mould they employ. There is
expendable mould casting and non-expendable mould casting. As the name implies, expendable
moulds are used for only one metal casting while permanent moulds are used for many. When
considering manufacturing processes, there are advantages and disadvantages to both.

Metal castings quality is determined by the casting properties of the metal:

1. Fluidity

2. Shrinkage

3. Shrinkage cavity

4. Shrinkage porosity

5. Surface quality

6. Resistance to cracks formation

Sand casting

A process where a molten metal is poured into a mould made from sand.
Green Sand Moulds:

A green sand mould is very typical in sand casting manufacture, it is simple and easy to make, a
mixture of sand, clay and water. The term green refers to the fact that the mould will contain
moisture during the pouring of the casting.

Manufacturing Considerations and Properties of Green Sand Moulds:

1. Has sufficient strength for most sand-casting applications

2. Good collapsibility

3. Good permeability

4. Good reusability

5. Least expensive of the moulds used in sand casting manufacturing processes

6. Moisture in sand can cause defects in some castings, dependent upon the type of metal
used in the sand casting and the geometry of the part to be cast.

Dry Sand Moulds:

Dry sand moulds are baked in an oven, (at 300F - 650F for 8-48 hours), prior to the sand-casting
operation, to dry the mould. This drying strengthens the mould and hardens its internal surfaces. Dry
sand moulds are manufactured using organic binders rather than clay.

Manufacturing Considerations and Properties of Dry Sand Moulds:

1. Better dimensional accuracy of sand cast part than green sand moulds

2. Better surface finish of sand cast part than green sand moulds

3. More expensive manufacturing process than green sand production

4. Manufacturing production rate of castings are reduced due to drying time

5. Distortion of the mould is greater, (during mould manufacture)

 6. Metal casting is more susceptible to hot tearing because of the lower collapsibility of the
mould

Skin Dried Moulds:

When sand casting a part by the skin dried mould process a green sand mould is employed, and its
mould cavity surface is dried to a depth of .5 - 1 inch. Drying is a part of the manufacturing process
and is accomplished by use of torches, heating lamps or drying it in air.

Manufacturing Considerations and Properties of Skin Dried Moulds:

1. The cast part dimensional and surface finish advantages of dry sand moulds are partially
achieved

2. No large oven is needed

3. Special bonding materials must be added to the sand mixture to strengthen the mould cavity
surface

Process

There are six steps in sand casting process:

1. Place a pattern in sand to create a mould.

2. Incorporate the pattern and sand in a gating system.

3. Remove the pattern.

4. Fill the mould cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mould and remove the casting.

 Plaster mould casting

Plaster mould casting is a similar technique to sand casting where Plaster of Paris is used to form the
mould for the casting, instead of sand.

Application of Plaster mould Casting:

Materials with low melting points such as aluminium, copper, magnesium and zinc can be cast by
this process. Can be used for making quick prototype parts

Process
There are six steps in plaster mould casting process:

1. Plaster is mixed, and the pattern is sprayed with a thin film of parting compound.

2. Plaster is then poured over the pattern.

3. The plaster sets, and the pattern is removed.

4. The mould is then baked to remove any excess water.

5. The dried mould is then assembled, preheated, and the metal poured.

6. Finally, after the metal has solidified, the plaster is broken from the cast part.

Evaporative casting

Evaporative-pattern casting is a type of casting process that uses a pattern made from a material
that will evaporate when the molten metal is poured into the moulding cavity. The most common
evaporative-pattern material used is polystyrene foam.

Properties and Considerations of Manufacturing by Evaporative Casting

1. If a core is need it is incorporated within the pattern. Therefore, placing and securing a core
in the mould cavity before the pouring of the metal casting is not a step in this
manufacturing process.

2. Flasks for this process are simple and not expensive.

 3. In manufacturing industry, patterns for expanded polystyrene metal casting will always
include the full gating system.

4. Very complex metal casting geometry can be produced using this process.

5. This manufacturing process can be very efficient in the production of metal castings for large
industrial runs. The main cost is to create the die to produce the foam polystyrene patterns.

6. This manufacturing process can be easily automated.

Application of Full mould Casting:

Materials cast with this process are aluminium, iron, steels, nickel alloys, copper alloys to produce
pump housings, manifolds, and auto brake components.

There are five steps in evaporative casting process:

1. Manufacture the polystyrene pattern.

2. The pattern is then placed in a flask and moulding sand is packed around it.

3. The molten metal is then poured into the mould without removing the pattern.

4. The molten metal is then allowed to harden within the sand mould.

5. Once solidified, the casting is removed.

 Investment casting

Investment (lost wax) casting is a method of precision casting complex near-net-shape details using
replication of wax patterns.

Application of Investment Casting:

Typically, materials that can be cast with this process are Aluminium alloys, Bronzes, Stainless steels,
Stellite etc. Glass mould accessory castings, Valves and fittings, Gears, Levers and Splines are some
of the popular usages.

Process The basic steps of the investment casting process are:

1. Manufacture the wax pattern for the process.

2. Assembly of these patterns onto a gating system.

3. The pattern is then dipped in a refractory slurry.

4. Melting the pattern to remove the wax material.

5. The ceramic mould is then heated to around 1000F-2000F (550C-1100C).

6. The metal casting is then poured while the mould is still hot.

7. The casting is allowed to set as the solidification process takes place.

8. Breaking the ceramic mould from the investment casting.

 Die casting

Die casting is a metal casting process that inserting molten metal under high pressure into a mould
cavity.
Application of Die Casting:

Most common materials used are small and medium sized parts made of aluminium, magnesium
and brass. Products include gears, splines, wheels, gear housings, pipe fittings, fuel injection
housings, and automotive engine pistons.

Process

There are four steps in die casting process:

1. Die preparation

2. Filling

3. Ejection

4. Shakeout
 Centrifugal casting

Centrifugal casting is a method of casting parts having axial symmetry. The method involves pouring
molten metal into a cylindrical mould spinning about its axis of symmetry.

Properties and Considerations of Manufacturing by Centrifugal Casting

1. A great manufacturing process for producing hollow cylindrical parts.

2. The metal casting's wall thickness is controlled by the amount of material added during the
pouring phase.

3. A very efficient industrial metal casting process, in terms of material usage.

4. Good surface finish and detail.

5. Good dimensional accuracy can be produced.

6. Material of high density and with few impurities is produced in the outer regions of
cylindrical part

7. This method can produce very large metal castings.

8. Centrifugal casting is a process that is capable of very high rates of productivity.

Applications of Centrifugal Casting: Typical materials that can be cast with this process are iron,
steel, stainless steels and alloys of aluminium, copper and nickel. Two materials can be cast by
introducing a second material during the process. Typical parts made by this process are pipes,
boilers, pressure vessels, flywheels, cylinder liners and other parts that are axi -symmetric.

Process

There are five steps in centrifugal casting process:

1. The mould wall is coated by a refractory ceramic coating (applying ceramic slurry, spinning,
drying and baking).

2. Starting rotation of the mould at a predetermined speed.

3. Pouring a molten metal directly into the mould (no rating system is employed).

4. The mould is stopped after the casting has solidified.

5. Extraction of the casting from the mould..

 Continuous casting

Continuous casting is a casting method, in which the steps of pouring, solidification and withdrawal
(extraction) of the casting from an open end mould are carried out continuously.

Properties And Considerations Of Manufacturing By Continuous Casting.

1. This process is used in commercial manufacture as a replacement to the traditional process

of casting ingots.

2. Piping, a common problem in ingot manufacture, is eliminated with the continuous casting
process. Structural and chemical variations in the metal of the casting, often present in
ingots, have been eliminated. When manufacturing with the continuous metal casting
process, the casting's material will possess uniform properties.

3. When employing continuous metal casting manufacture, the castings will solidify at 10 times
the rate that a casting solidifies during ingot production.

4. With less loss of material, cost reduction, higher productivity rate, and superior quality of
castings, continuous casting manufacture is often the choice over ingot production.

5. A continuous casting manufacturing process will take considerable resources and planning to
initiate, it will be employed in only very serious industrial operations.

Process

There are five steps in centrifugal casting process:

1. Molten metal is poured into a tundish.

2. The metal casting moves quickly through the mould, in the continuous manufacture of the
metal part.

3. The mould in the continuous casting process is water cooled.

4. The long metal strand is moved along at a constant rate, by way of rollers