CASTING

By – Mritunjay Kumar
Assistant Professor
GEC Lakhisarai
M.Tech IIT (ISM) Dhanbad
1
 Manufacturing
• It is the process of converting raw material or semi
finished product into a finished product.
• It is a value addition process to the raw material.
Manufacturing
Raw material Process Product
• Classification :
1. Casting
2. Forming
3. Fabrication Process
4. Material removal Process
5. Powder metallurgy
2
 Casting
• It is a manufacturing process by which a liquid metal is
usually poured into a mould cavity of the desired shape and
then allowed to solidify.
• The solidified part is also known as a casting, which is
ejected or broken out of the mould to complete the process.
Advantage :
• Complex shape of the objects can be produce.
• Tool used in this technique are less expensive in compare
to other process.
• Brittle and ductile material can be produced by casting.
• Large size object can be produced by casting only.
Ex- Lathe bed, Engine block, Turbine housing, etc. 3
 Limitations
• Poor surface finish.
• Laborious process.
• Dimensional inaccuracy.
• Possibility of defects in a castings (Gas defect).
• Non uniform mechanical properties due to non uniform
cooling.
• Fine grains, course grains, colummar grains & equi-axed
grains.

4
 Steps involved in Casting
1. Preparation of moulds & patterns
2. Melting & pouring of molten metal
3. Solidification & further cooling to room temperature
4. Ejection of casting from mould
5. Defects and inspection

5
Casting terms

6
• Mould :
• A mould is an assembly of two or more metal blocks,
or bonded refractory particles (sand) consisting of a
primary cavity.
• The mould contains secondary cavities for pouring &
channeling the liquid material into the primary cavity to
act as reservoir.
• Flask :
• A moulding flask is one which holds the sand mould
intact. It is made up of wood for temporary applications
or metal for long‐term use.
• Cope : Top half of moulding box.
• Drag : Bottom half of moulding box.
• Cheek : Intermediate molding flask used in 3 piece.7
• Parting line: Separates cope & drag.
• Pouring basin:
• Small funnel shaped cavity at top of the mould into
which molten metal is poured.
• It is design to reduce the velocity of the liquid metal
which is enter into the sprue to minimize the erosion.
• Sprue: The passage through which the molten metal
from the pouring basin reaches the mould cavity.
• Runner: The passage ways in the parting plane
through which molten metal flow is regulated before
they reach the mould cavity.
• Gate: The actual entry point through which molten
metal enters the mould cavity in a controlled rate. 8
• Core: It is mainly used for making hollow cavities in
castings
• Core print: projections on the pattern and recess
inside the cavity to position the core properly.
Core sand:
Green sand core
+
Organic binders
(linseed oils + molasses, etc)

• Net force on core(P) = Vg(ρm ̶ ρc)

Where, V = volume of core
ρm = density of liquid metal
ρc = density of core material
9
• Chaplet : Metallic objects
used to support the core inside
the cavity. Made of same
material as the casting.
• Chills :
• At minimum X-s/c in mould cavities
to increase the heat transfer rate,
metallic objects are placed known as
chills.
• These are made of high melting point
temp. & high thermal conductivity
materials.
• Uniform solidification & directional
solidification can be possible. 10
• Padding :
• At critical X-s/n to maximize the heat transfer rate
and to minimize the mould erosion, metallic objects
are provided known as padding.
• By providing padding uniform solidification and
directional solidification can be possible.

• Riser : It is a reservoir of molten metal provided in the

casting so that hot metal can flow back into mould
cavity when there is a reduction in volume of metal due
to solidification. 11
Question 1.
One direction solidification in casting can be
improved by using-
[SSC-JE : 2015]
a) Chaplets & padding
b)Chills & chaplets
c) Chills, chaplets & padding
d)Chills & padding

12
Question 2.
The main purpose of chaplets is
[IES: 2001]
a) To ensure directional solidification
b)To provide efficient venting
c) For aligning the mould boxes
d)To support the cores

13
Question 3.
The primary purpose of a sprue in a casting mould is
to
[GATE : 2002]
a) Feed the casting at a rate consistent with the rate of
solidification
b)Act as a reservoir for molten metal
c) Feed molten metal from the pouring basin to the gate
d)Help feed the casting until all solidification takes
place 14
Question 4.
Which of the following is the correct statement?
Gate is provided in moulds to
[IES: 2007]
a) Feed the casting at constant rate
b)Give passage to gases
c) Compensate for shrinkage
d)Avoid cavities

15
Question 5.
Which of the following provides an added
projection on a pattern and forms a seat to
support and locate the core in the mould
[SSC-JE ]
a) Mould print
b)Core print
c) Drag
d)Cheek
16
 Pattern
Pattern is a replica of the final casting to be made with
some modifications in the form of allowances and core
prints.
Allowances : This is provided due to contraction in
casting during solidification.
1. Shrinkage or contraction
2. Draft or taper
3. Machining or finishing
4. Rapping or Shaking
5. Distortion or Camber

17
Shrinkage or contraction allowance

18
• When the liquid metal is allow to solidify in the cavity
there is a possibility of shrinkage of the material. Due to
this size of the casting will be reduce with compare to
actual size of the casting.
• When the liquid metal is cooling from pouring
temperature to freezing temp. , the shrinkage is known as
liquid shrinkage.
• During phase transformation the shrinkage is
solidification shrinkage.
• When the solid casting is cooling from freezing temp. to
ambient temp. the shrinkage is solid shrinkage.
• Liquid and solidification shrinkage can be compensated
by providing riser. These values are expressed as
percentage of shrinkage volume of casting. 19
Question 6.
Shrinkage allowance is made by
[SSC-JE : 2010]
a) Adding to external & internal dimensions
b)Subtracting from external & internal dimensions
c) Subtracting from external dimensions & adding to
internal dimensions
d)Adding to external dimensions & subtracting from
internal dimensions.
20
Note:-
• Brass is having maximum solid shrinkage which
requires large size pattern.
• Aluminium is having maximum liquid shrinkage.
It requires more volume of the riser.
• Liquid and solid shrinkage will be maximum for steel
material.
Gray cast iron:
• Negative shrinkage allowance
(reduced pattern size, 7-10mm/m).
• Gray cast iron material slightly expand when cooling,
this is due to graphite precipitates as a flakes and it will
occupied more volume because of less density.
21
• Solid shrinkage is compensated by increasing the size of
the pattern in the form of shrinkage allowance. These
values are expressed in terms of linear dimensions.

Shrinkage values for different materials

• Invar & Bismuth – negligible
• White metal - 5mm/m
• Cast iron -10mm/m
• Aluminium -13mm/m
• Copper -16mm/m
• Steel - 20mm/m
• Brass - 3mm/m 22
Question 7.
For gray cast iron, the pattern shrinkage
allowance is of the order of
[SSC-JE ]
a) 2 to 5 mm/m
b)5 to 7 mm/m
c) 7 to 10.5 mm/m
d)10.5 to 13.5 mm/m

23
Question 8.
Which of the following materials will require the
largest size of riser for the same size of casting?
[IES-1995]
a) Aluminium
b)Cast iron
c) Steel
d)Copper

24
Question 9.
Which of the following materials will require the
largest shrinkage allowance, while making a
pattern for casting?
[IES-1995]
a) Aluminium
a) Brass
b)Cast iron
c) Plain carbon steel
25
Question 10.
Shrinkage allowance on pattern is provided to
compensate for shrinkage when
[IES-1995]

a) The temperature of liquid metal drops from pouring to

freezing temperature
b) The metal changes from liquid to solid state at freezing
temperature
c) The temperature of solid phase drops from freezing to
room temperature
d) The temperature of metal drops from pouring to room
temperature 26
 Draft or Taper Allowance

• For easy removal of the pattern from the mould, for the
vertical surface of the pattern, draft or taper will be
provided.
• Due to this, continuous contact between pattern &
mound surface will be decreases and tearing of the
mould will be reduced. 27
 Machining or Finished allowance

• Casting objects are not having smooth surface finish.

To get smooth surface finish of the casting machining is
required , due to this size of the casting will be reduced.
• To overcome this size of the pattern should be increased
by adding machining allowance.
28
Question
Calculate the dimensions of the pattern for the casting
shown below by considering machining allowance of 1mm
on each surface.

Note:
It is a positive allowance. It is added for external and
internal dimensions. By adding, the external dimensions
of the pattern will be increases and internal dimensions
will be reduced.
29
 Rapping or Shake allowance
• For easy removal of the pattern from the mould some
clearance is required between pattern and mould surface.
• Due to shaking of the pattern, size of the cavity will be
increase and clearance is created.
• To overcome this size of the pattern will be reduced by
considering shake allowance.

30
 Distortion or Camber
• Depending on shape and size of the casting due to
difference in shrinkage there is a possibility of distortion
of the castings.
• To overcome this distortion allowance is provided on
the pattern opposite to the direction of distortion.
• These values are depends on the length to thickness
ratio(L/t) of the casting. It will increases if ratio is
increases.

31
 Pattern material
• Wood : Easy o make. Not very dimensionally stable.
Commonly used Teak, Mahogany, deodar, white pine
wood.
• Metal: More expensive.
• Dimensionally more stable and durable.
• Used for mass production.
• Produced by wooden pattern, this is why on wooden
pattern double shrinkage allowance is added & wooden
pattern is known as Master pattern.
• Commonly used Al, Brass, C.I, Steel, etc.
• Plastics : Also known as expandable or disposable
pattern. Polystyrene, polyurethane foam, pvc, epoxy,
rubber, etc.
• Wax : Used in investment casting. 32
 Types of Pattern
• Solid or Single piece pattern :

• It is used when the object to be produced is very simple

in shape and size.
• It is the most inexpensive of all type of pattern.
• Used for small scale production.

33
 Split or two piece pattern

• If the complexity of the pattern will be more it is

difficult to remove the pattern by assuming single piece
pattern.
• In this case pattern can be split into two parts along the
parting surface.
• The two halves of the pattern must be aligned by making
use of the dowel pins. 34
 Loose piece pattern

• In the pattern are having projections or undercuts it is

difficult to remove pattern from the mould by using split
pattern.
• In this case the projections of the pattern will be made
as loose pieces.
• These loose pieces can be removed from the mould
after removing the main part of the pattern. 35
 Gated pattern

• Used for simple & small size casting in mass production.

• In this no. of patterns along with gating elements will be
made as a single pattern.
• Cavities are formed along with gating elements.
36
 Match plate pattern

• Produce complex shape of objects in mass production.

• In this no. of patterns are splitted into no. of split pieces
& pieces added on both side of the match plate along
with gating element.
37
Question 11.
Match plate pattern used in
[SSC-JE : 2017]
a) Green sand moulding
b)Bench moulding
c) Pit moulding
d)Machine moulding

38
Question 12.
The pattern adopted for those castings where there
are some portions which are structurally weak and
are likely to break by the force of ramming are
called:
[SSC-JE]
a) Loose piece pattern
b)Follow board pattern
c) Skeleton pattern
d)Single piece pattern
39
 Cope and drag pattern

• These casting can be used for castings which are heavy

and inconvenient for handling.
• Similar to split patterns. In addition to splitting the
pattern, the cope and drag halves of the pattern along
with the gating system and riser system . 40
 Sweep pattern

• It is used to produce 3D object with the help of 2D

plane object.
• It is suitable for axi-symmetric object only.
Ex- Cone, cylindrical shape, well shaped objects, etc.

41
 Skeleton pattern

• Produced by adding small size wooden work pieces in

the form of skeleton and by adding sand on the
skeleton desired shape of the pattern produced.
• Used for shell, bend, etc
42
 Follow board pattern

• If the pattern are having structurally weak members due

to ramming forces there is a chance of breaking of the
pattern.
• To overcome this, patterns are supported by follow
board. 43
Question 13.
Sweep pattern is used for moulding parts having
[SSC-JE ]
a) Rectangular shape
b)Elliptical shape
c) Uniform symmetrical shape
d)Complicated shape having intricate details

44
Question 14.
For mounting several patterns at a time, the
following type of pattern is used
[SSC-JE ]
a) Combined pattern
b)Loose piece pattern
c) Sweep pattern
d)Match plate pattern

45
Question 15.
Loose piece patterns are
[SSC-JE ]
a) A sort of split pattern
b)Used when the pattern cannot be drawn from the
mould
c) Similar to core print
d)Never used in foundry work

46
Question 16.
The moulding sand can contain following
percentage of maximum quantity of moisture
[SSC-JE ]
a) 2.5%
b)8%
c) 5%
d)12%

47
 Moulding sand
• Composition of moulding sand :
Silica — 70-80%
Clay — 10-20%
Water — 2-8 %
Additives — 1-4%
• Green sand : Moulding sand contains 2-8% of
moisture is called green sand. And the corresponding
strength of the mould is known as Green strength.
• Dry sand : When the liquid metal is entering to the
cavity due to high temp. of the liquid metal by
evaporating the moisture around the cavity then sand
will became dry & corresponding strength of the mould
is Dry strength. 48
• Hot sand : After becoming the sand dry still liquid
metal is having more heat then the sand will become hot
& strength of the sand will become hot & strength of the
mould is hot strength.
• Facing Sand : The small amount of carbonaceous
material sprinkled on the inner surface of the mould
cavity to give a better surface finish to the castings.
• Baking sand : This is made up of used and burnt sand.
• Loam sand : It contains 50% sand and 50% clay.
• Parting sand : It is pure silica sand without clay and
water which is used to avoid sticking of the mould with
other surfaces.
49
Question 17.
In a green sand moulding process, uniform
ramming leads to
[SSC-JE ]
a) Less chances of gas porosity
b)Uniform flow of molten metal into the mould
cavity
c) Greater dimensional stability of the casting
d)Less sand expansion type of casting defect
50
Question 18.
Green sand mould indicates that
[GATE 2011 ]
a) Polymeric mould has been cured
b)Mould has been totally dried
c) Mould is green in colour
d)Mould contains moisture

51
Question 19.
Small amount of carbonaceous material sprinkled
on the inner surface of mould cavity is called
[IES2008 ]
a) Backing sand
b)Facing sand
c) Green sand
d)Dry sand

52
• Permeability : Ability of moulding sand to allow the
gases t escape is known as permeability. It is expressed
by permeability number.
Pn = VH/PAT
H = D = 2 inch = 2 x 2.54 cm = 5.08 cm
Pn = 501.28/PT
Pn = 50-120
Where ,
V = vol. of air passing through the specimen = 2000cc.
H = height of the standard cylindrical specimen
P = Difference of pr. of air passing through the
specimen(gm/ cm²)
A = cross – sectional area, (cm²)
T = Time taken by the air to pass through this
specimen(min) 53
 Properties of moulding sand
• Refractoriness : It is the ability of the moulding sand
to withstand high temperature of the liquid metal
without fusion. M.P of Silica - 1710⁰C.
• Flowability : it is the ability of the moulding sand to
move to all the corners of the mould box due to
ramming.
• Strength : To retain shape and size of the moulding
cavity and to withstand force supplied by the liquid
metal on the mould surface, mould must have sufficient
strength (green strength, dry strength, hot strength).

54
• Hardness :
• To minimize the erosion and to withstand the forces on
the mould surface mould must require sufficient hardness.
• Average mould hardness no. is 60-80.
• If it is more than 80 permeability of the mould is
decreases, if it is less than 60 dimensional stability of the
casting will be decreases.
• Collapsibility :
• Ability of the moulding sand due to which mould surface
will not offer any resistance due to contraction of the
casting.
• This can be improved by adding saw dust or wood floor
additives.
55
• Adhesive property :
• Bond formation between two different materials.

• Cohesive property
• Bond formation between similar particles.

• Moulding sand also requires high thermal

conductivity and low coefficient of thermal expansion.

56
 Additives used in Moulding Sand
• Strength & hardness : Linseed oils, molasses, etc
• Hot strength : Fe₂O₃ + Al₂O₃
• Surface finish : Coal dust
• Collapsibility & permeability : Saw dust, Wood floor.

57
Question 20.
Permeability of a foundry sand is
[SSC-JE : 2010]
a) Porosity to permit the escape of gases/air
b)Fineness of sand
c) Distribution of binder in sand
d)Capacity to hold moisture.

58
Question 21.
Permeability is poor for-
[SSC-JE : 2013]
a) Fine grains
b)Medium grains
c) Coarse grains
d)Rounded grains

59
Question 22.
Hardness of green sand mould increases with
[SSC-JE]
a) Increase in moisture content beyond 6%
b)Increase in permeability
c) Decrease in permeability
d)Increase in both moisture content & permeability

60
Question 23.
Strength and permeability of served sand are
related to
[SSC-JE : 2017]
a) Grain size
b)Clay content
c) Hardness
d)Moisture content

61
Question 24.
For steel castings, the following type of sand is
better-
[SSC-JE : 2014]
a) Fine grains
b)Coarser grains
c) Medium grains
d)Fine grains, coarser grains & medium grains all are
equally good
62
 Elements of Gating Design
• Pouring basin
• Strainer (ceramic material)
• Sprue
• Sprue base well
• Splash core
• Runner
• Skimbob
• Gate
• Cavity
• Riser

63
Question 25.
Light impurities in the molten metal are prevented
from reaching the mould cavity by providing a
[gate ]
a) Strainer
b)Button well
c) Skim bob
d)All of the above

64
 Casting yield

• It is the ratio between useful metal in the mould to the

total volume of the metal which is enter into the mould.
𝑣𝑐
Casting yield =
𝑣𝑐 + 𝑣𝑔
Where,
𝑣𝑐 = Volume of metal entering into the cavity
𝑣𝑔 = Volume of metal enters into mould other than casting.

65
Sprue design

66
• Air aspiration effect
• If the atmospheric gases will be absorbed into the
gating element they will mixed up into the liquid metal
& pump gas defect this is known as air aspiration
effect.

• To avoid the air aspiration effect ideal shape of the

sprue is parabola. To reduce the manufacturing
difficulty shape of the sprue will be considered as
tapered cylinder.

67
 Type of Gate or Ingate
• Top Gate : Liquid metal enters into cavity directly
from bottom of the sprue at atmospheric pressure.
Possibility of turbulence and splashing. Only used for
ferrous material. Favorable temp. gradient. Time taken
to fill the cavity will be less.

• Bottom Gate : Liquid metal entering to the cavity

from the bottom. No mould erosion, no turbulence &
splashing. Used for non- ferrous material. Time taken to
fill the cavity will be high. Unfavorable temp. gradient.

68
Top Gate

Bottom Gate

Parting line Gate

69
 Step Gate

• Parting line gate : most commonly used gating

system to get the advantage of both top and bottom
gate. Liquid metal can be entering the cavity within a
given time without turbulence & splashing .

• Step Gate : Used for heavy & large castings. In this

no of gates are provided in the form of steps. Gradual
filling of liquid metal into the cavity.
70
 Pouring time/ Filling time
• Time taken to fill the mould with top gate :
𝑣𝑚
𝑡𝑓 =
𝐴𝑔 𝑉𝑔

• Time taken to fill the mould with bottom gate :

2𝐴𝑚
𝑡𝑓 = ℎ𝑡 − ℎ𝑡 − ℎ𝑚
𝐴𝑔 𝑣𝑔

71
 Fluidity
• Ability of the liquid metal to flow into the mould cavity
is known as fluidity. It is the property of the liquid
metal. It is determined by conducting a spiral test.

Property Fluidity
Pouring temp.
Viscosity
Density
Moisture in sand
Surface finish of cavity
Thermal conductivity
72
Question 27.
Fluidity is greatly influenced by
[SSC-JE ]
a) Carbon content of molten metal
b)Melting temperature of molten metal
c) Inoculant addition
d)Pouring temperature of molten metal

73
 Choke Area
• It is the minimum cross-section area in all the gating
elements. It will control the flow of liquid metal which
enter into the cavity.

• It is the first parameter to be calculated in all the gating

elements.
𝑚
𝐶𝐴 =
𝜌𝑡𝑓 𝐶𝑑 2𝑔ℎ𝑡

74
 Type of gating system

• Pressurized gating system

• Unpressurized gating system

75
 Pressurized gating system
• Choke area is at the cross-section of the gate.
• Liquid metal entering into the cavity with more velocity.
• There is a chance of turbulence & splashing of a liquid
metal.
• It can be used for a ferrous material.
• There is no possibility of air aspiration effect.
• Casting yield is maximum.

76
 Unpressurized gating system
• Choke area is at the cross-section of sprue.
• Liquid metal is enter into a cavity with less velocity.
• There is no possibility of turbulence & splashing of the
liquid metal.
• Used for non-ferrous materials.
• There is a possibility of air aspiration effect.
• Casting yield is less.

77
 Gating ratio
• It is the ratio between are of sprue to the area of runner to
the are of the gate.

As: Ar : Ag

• 1:2:3 Unpressurized gating system

• 3 : 2 :1 Pressurized gating system
• 1:2:1
• 3: 1.5: 0.5

78
Question 28.
In a gating system, the ratio 1: 2: 4 represents
[SSC-JE ]
a) Sprue base area: runner area: ingate area
b)Pouring basin area: ingate area: runner area
c) Sprue base area: ingate area: casting area
d)Runner area: ingate area: casting area

79
 Solidification time
• Chvorinov’s Principle :
𝐕 2
tₛ ∝
𝐒𝐴

𝐕 2
tₛ = K
𝐒𝐴

K = Solidification factor (s/m²)

80
 𝑣 𝑎3 𝑎
1. Cube = 2=
𝑆𝐴 6𝑎 6

2. Sphere 𝑣 𝐷
=
𝑆𝐴 6
𝜋 2
𝑣 ⅆ ℎ
3. Cylinder
= 4
𝑆𝐴 2𝑥 𝜋 ⅆ2 + 𝜋 ⅆℎ
Δ

𝑣 𝑙𝑏ℎ
4. Cylinder =
𝑆𝐴 2 𝑙𝑏 + 𝑏ℎ + 𝑙ℎ
81
Question 29.
According to chvorinov’s equation, the
solidification time of a casting is proportional to:
[SSC-JE ]
a) v²
b)v
c) 1/v
d)1/v²

82
 Riser
𝑆𝐴
• :-
𝑉
Cooling characteristics
Minimum
• For a given volume of riser sphere is having minimum
surface area with the volume ratio.
• Due to availability of the liquid metal at the centre of
the spherical riser it is difficult to feed the liquid metal
to the cavity to compensate shrinkage.
• It is not used as a shape of the riser.
• Cylinder will be used as a shape of a riser.

83
 Caine’s method
𝑆𝐴 𝑆
𝑉 𝐶 𝑆𝐴 𝑟
• F𝑟𝑒𝑒𝑧𝑖𝑛𝑔 𝑟𝑎𝑡𝑖𝑜(𝑋) = 𝑆𝐴 = 𝑉
𝑉 𝑟 𝑆𝐴 𝑐

𝑎
• X= +𝑐
𝑦−𝑏

𝑉𝑟
• 𝑦=
𝑉𝑐

84
• For complex shape of the casting, calculation of surface
area to volume ratio is difficult.
• By using this method we can also check weather
calculated dimensions of the riser is correct or not using
the graph.
• Shape factor :
SF = (L + W)/ T

85
 Modulus method
𝑉
Modulus (M) =
𝑆𝐴

• Mr = 1.2 Mc

86
Question 30.
The ratio of surface area of volume for a unit
volume of riser is minimum in case of
[SSC-JE ]
a) Cylindrical riser
b)Spherical riser
c) Hemispherical riser
d)Cuboids riser

87
• Condition for minimum surface area , maximum
solidification time in case of cylindrical riser :

• side riser: h꓿d SA/V ꓿ 6/d Vs ꓿ π/4 xd3

• Top riser: h ꓿ d/2 SA/V ꓿ 6/d Vt ꓿ π/8 x d3

88
• Methods to increase the performance or
efficiency of the riser :
• By providing insulating material on the top surface &
circumference of the riser.
• By providing exothermic material on top surface of the
riser.
• Due to exothermic reaction heat will release & it will
supply to the liquid metal in the riser.
• Due to this more longer time the metal will be in liquid
state in the riser.

89
 Classification of Casting Technique
• Expandable casting
• Sand Moulding
• Shell Moulding
• Investment casting
• Full Moulding
• CO₂ Moulding
• Permanent Casting
• Centrifugal Casting
• Die casting
• Slush casting
• Continuous Casting
90
Shell Moulding

91
• It is the process in which the sand mixed with a
thermosetting resins like silica is allowed to come in
contact with a heated metallic pattern, so that a thin &
strong shell of mould is formed around the pattern.
Advantages :
• Dimensionally more accurate
• Improved surface finish
• Used for small castings
• Wastes of moulding material is less.
Limitations :
• Patterns are very expensive
• Highly complicated shapes cannot be obtained.
92
Applications :
• Cylinder blocks
• Cylinder heads of IC Engines
• Rocker arms,
• Valve plates of refrigerator, etc

93
Question 31.
The main advantage of shell moulding is that
[SSC-JE : 2017]
a) A metallic pattern is used
b)The moulds are stronger
c) Thin sections can be easily produced
d)High complex sections can be easily obtained

94
Question 32.
The mould in shell moulding process is made up of
which of the following?
[SSC-JE :]
a) Gypsum + setting agents
b)Green sand + clay
c) Sodium silicate + dried sand
d)Dried sand + phenolic resin

95
Investment Casting

96
• To produce complex shape of the object with more
accuracy & surface finish which are produced by high
melting point material & high strength materials this
technique can be used.

• Pattern is produced by wax material.(expandable

pattern)

• Fine grain ceramic particles will be added on to the wax

pattern in the presence of slurry to produce ceramic cell.

• This process is carried out under vacuum conditions (to

minimize gas defects) 97
Application :
• Turbine blades
• Jet engine parts
• Medical implants
• Dentures(surgical instruments)
• Gold ornaments

98
Question 33.
Which of the following casting methods utilizes
wax pattern
[SSC-JE ]
a) Shell moulding
b)Plaster moulding
c) Slush moulding
d)Investment casting

99
Question 34.
Investment casting is used for
[SSC-JE ]
a) Shapes which are made by difficulty using complex
patterns in sand casting
b)Mass production
c) Shapes which are very complex and intricate and
can’t be cast by any other method
d)Stainless steel parts.
100
Question 35.
Which of the following casting processes uses
expandable pattern & expandable mould?
[SSC-JE ]
a) Shell mould casting
b)Investment casting
c) Pressure die casting
d)Centrifugal casting

101
Question 36.
The most preffered process for casting gas turbine
blades is
[SSC-JE ]
a) Die casting
b)Investment casting
c) Pressure die casting
d)Sand casting

102
Question 37.
The proper sequence of investment casting steps is:
[SSC-JE ]
a) Slurry coating – pattern melt out – shakeout – stucco
coating
b) Stucco coating – Slurry coating –– shakeout – pattern
melt out
c) Slurry coating –stucco coating – pattern melt out –
shakeout
d) Stucco coating – shakeout – Slurry coating –pattern melt
out
103
Full Moulding/ Evaporative pattern
casting/ Expandable pattern casting
Molten Metal

Plaster of Paris

104
• Used to produce complex shape of the object with
smooth surface finish.
• Pattern : Made up of plastics (polystyrene,
polyurethane, foam, pvc, epoxy, rubber, etc)
• Mould : Prepared using plaster of paris.
• Used for low M.P material.
Application :
• Fitting
• Tooling
• Lock components
• Motor casings, etc.

105
CO₂ moulding

106
• Not used clay and water(used sodium silicate binder).
• Used for large castings.
• Hardness and strength of the mould is high.
• Mould is prepared by adding sodium silicate binder and
CO₂ gases passes through the mould to increase the
hardness and strength of the mould.

Application :
• Lathe bed, etc

107
 Permanent Moulds
• True centrifugal castings :

108
• In this process mould is rotated rapidly about its central
axis as the metal is poured into it.

• Due to centrifugal force high density pure metal can be

forced away from the centre & less density impurities
can be collected towards centre.

• Due to faster cooling rate fine grain structure with high

density can be produced.

• Castings are having more Hardness and Strength.

• To produce hollow cylinder shape of object in mass

production without using the core this technique can be
used. 109
• Accuracy & surface finish is very high.
• It is mainly used for hollow axisymmetric or cylindrical
shape of objects only.
• Casting yield is 100%.

Application :
• Hollow cylindrical pipes
• Gun barrels
• Large size buses
• Propeller shaft

110
Semi centrifugal casting

111
• More material at the outer circumference as compare to
the centre.
• Liquid metal enters into the centre of the die through
sprue by means of gravity force and outer portion is
filled by purely centrifugal action.
• Rotated along vertical axis.
• Casting yield is less compare to centrifugal castings.

Application :
• Pulleys
• Gear wheels
• Spoked wheels
• Small sized flywheels,
etc 112
 Centrifuging

• Liquid metal enters into

the centre of the die
through the sprue by
means of gravity force
and forcing away from the
centre through runner into
the cavity with non
uniform centrifugal force
known as centrifusing.

113
• Produce unsymmetrical objects in mass production.
• Suitable for small jobs in any shapes.
• Axis of the rotation of the mould not coincides with
axis of the objects.
• Low speed
• Casting yield is very less(50-60%)

114
Question 38.
Centrifugal method of casting is used to
[SSC-JE ]
a) Ensure purity and density at extremities of a casting
b)Cast symmetrical objects
c) Obtain high density and pure castings
d)Use heavy cast iron mould to act as chill

115
Question 39.
The core in the centrifugal casting is made of
[SSC-JE ]
a) Carbon steel
b)Properly treated sand
c) Plastics
d)No core is used

116
Question 40.
The impurities in true centrifugal casting
[SSC-JE ]
a) Get collected at outer surface
b)Mix up thoroughly throughout
c) Get collected at the inner surface
d)Get collected in the middle portion in between and
outer surface.

117
Question 41.
Centrifugally cast products have
[SSC-JE ]
a) Large grain structure with high porosity
b)Fine grain structure with high density
c) Fine grain structure with low density
d)Segregation of slag towards the outer skin of the
casting.

118
 Die casting
• Preparation of components by injection of molten metal
at high pressure into a metallic die.
• Pressure is maintained during solidification.

Type of die casting

• Gravity die casting
• Pressure die casting
1. Hot chamber die casting
2. Cold chamber die casting

119
Gravity Die Casting

120
• Liquid metal enters into a die by means of gravity
force only.
• Produce simple of casting only.
• Surface finish of the casting will be very high due to
fast rate of solidification.
• Fine grain structure will be develops.

Application :
• Piston used in automobiles(Al alloy).

121
Hot Chamber Die Casting

122
• Liquid metal can be enter into the die under external
plunger force.
• Furnace is integrated with casting system.
• Liquid metal is solidified under external pressure.
• Complex parts are possible
• Better mechanical properties.
• Very high surface finish.
• maximum production rate
• Excellent dimensional accuracy
• Used for low melting point material : lead, tin, zinc
• Thin sections are possible.

123
Cold chamber die casting

124
• Metal is heated in a separate crucible.
• Cast high melting point metals like Al, Mg, Cu & its
alloys(brass).
• High pressure used.
• Mainly Used to produce complex shapes
• Size of the castings are limited to 30kg.(small size
component)
• Production rate is maximum
• Better mechanical property
• Extremely smooth surface.
• Excellent dimensional accuracy

125
Application :
• Carburetors
• Crank cases
• Valve bodies
• Fuel injection pump parts
• Small size connecting rod & cranks.
• Toys

126
Question 42.
The chief advantage of die casting is:
[SSC-JE : 2017]
a) Possibility of incorporating thick sections in small
castings
b)Casting of inserts is possible
c) Wide tolerance are possible
d)High production rates are possible

127
Question 43.
The hot chamber die casting method is used to cast
[SSC-JE ]
a) Brass
b)Magnesium
c) Aluminium
d)Alloys of lead, tin and zinc.

128
Question 44.
In cold chamber method of die casting
[SSC-JE ]
a) Only low melting point metals can be cast
b)High melting point metals can be cast
c) Die is kept hot by electrical heating
d)Die is kept cold by circulating water.

129
Question 45.
The process of pouring molten metal in the cavity
of a metallic mould by gravity is known as :
[SSC-JE : 2010]
a) Permanent mould casting
b)Pressed casting
c) Shell moulding
d)Die casting

130
Slush Casting

131
• Used to produce thin & hollow castings of required
thickness without using core.
• Liquid metal will be allow to solidify on the die for
sufficient time.
• After getting sufficient thickness of the casting, by
rotating the die unsolidified liquid metal can be
removed from die.
• This is also known as partial solidification.

132
Application :
• Thin sections
• Hollow thin sections
• Toys
• Decorative items
• Thin ornaments
• Hollow statues
• Lamp bases, etc

133
Question 46.
Ornaments, statues, toys etc. are cast by
[SSC-JE ]
a) Die casting
b)Pressed casting
c) Centrifugal casting
d)Slush casting

134
Question 47.
Ornaments are cast by-
[SSC-JE : 2017]
a) Continuous casting
b)Slush casting
c) Die casting
d)Centrifugal casting

135
Question 48.
The process of making hollow castings of desired
thickness by permanent mould without the use of
cores is known as-
[SSC-JE : 2015]
a) Die casting
b)Slush casting
c) Pressed casting
d)Centrifugal casting
136
Question 49.
Plastic toys are usually produced by using:
[SSC-JE : 2014]
a) Shell moulding
b)Green sand moulding
c) Plaster moulding
d)Injection moulding

137
Continuous casting

138
• Used to produce long length metallic objects
continuously from the liquid metal.
• Liquid metal will be allowed through die opening.
• The output of the die is solid crust on which water is
spread to cool the material at faster rate.
• Due to this Solid crust is will be converted into solid
object.
Applications :
• Long length bars
• Rods
• Slab
• Sheet, etc.

139
Question 50.
The mould for casting ferrous materials in
continuous casting process is made of
[SSC-JE ]
a) Low carbon steel
b)Medium carbon steel
c) High carbon steel
d)copper

140
 Cleaning of casting
Fettling :
• Breaking the mould by using vibrating mechanism &
separating the gating elements from the casting.
Shot & Sand Blasting :
• If hardened steel balls along with air pressure is used for
cleaning known as shot blasting.
• If sand particles will be used then it is known as sand
blasting.

141
 Casting defects
• Gas defects
• Moulding material & methods defects
• Gating design defects
• Pouring metal defects
• Metallurgical defects
• Other defects

142
 Gas defects

• Blow holes : the gas defect formed inside the casting.

• Scar : A gas defect found on the flat surface of the
casting.
• Blister : A scar is covered by thin layer of metal is
called blister.
• Pin hole porosity : Small size gas hole formed due to
hydrogen gas.

143
144
145
 Molding material and methods defects
• It forms mainly due to improper ramming.
• Drop & Dirt : If silica sand particles will be
dropped from cope to drag box will form a defect on
the top surface of the casting known as Drop and at the
bottom surface of the casting is Dirt.
• Cuts & Washes : At critical cross-section in the
mould cavity moulding sand will be washed into the
cavity & form a defect known as Cuts & Washes.
• Scab : Liquid metal will be penetrated in the sand
layers in the cope box.

146
• Gating design defect:
• Shrinkage cavity : Due to improper riser design
the cavities are formed due to shrinkage of the
material.
• Pouring metal defects :
• Misrun : Due to lack of fluidity of the liquid metal
before reaching the cavity, the liquid metal will start
solidification will form me a defect knows as misrun.
• Cold shut : when two stream of liquid metal will not
fused together properly will form a defect known as
cold shut.
147
• Metallurgical defects :
• Hot tears : Cracks forms due to non uniform cooling,
residual(internal) stresses developed in the casting
which results the formation of cracks known as hot
tear.

• Other defects :
• Mould shift : improper alignment of cope and drag
box the defect is formed known as mould shift.
• Core shift : core is shifted from original position a
defect is formed known as core shift.

148
149
Question 51.
Which of the following is not the casting defect?
[SSC-JE : 2010]
a) Hot tear
b)Blow hole
c) Scab
d)Decarburization

150
Question 52.
Misrun is a casting defect which occurs due to
[SSC-JE]
a) Very high pouring temperature of the metal
b)Insufficient fluidity of the molten metal
c) Absorption of gases by the liquid metal
d)Improper alignment of the mould flasks

151
Question 53.
Two streams of liquid metal which are not hot
enough to fuse properly result into a casting defect
known as
[SSC-JE]
a) Cold shut
b)Swell
c) Sand wash
d)Scab
152
Question 54.
Scab is a
[SSC-JE]
a) Sand casting defect
b)Machining defect
c) Welding defect
d)Forging defect

153
Question 55.
Hot tears are the result of which of the following?
[SSC-JE : 2011]
a) Lower permeability
b)Lower green strength
c) More fins
d)Restraint of contraction

154
Question 56.
Non uniform ramming of moulding sand may lead
to the following casting defect-
[SSC-JE : 2014]
a) scabs
b)swells
c) Blow holes
d)bends

155
 Inspection of Casting
• Radiographic test: Internal hot tear, voids, porosity,
cracks defect can be detected.
• Both x-rays & ℽ-rays used.
• Darker in contrast at detected points.
• Ultrasonic inspection:
Internal cracks in casting.
• Ultrasonic signal is send to the casting.
• When encountering a discontinuity, signal is reflected
back.
• The time interval b/w sending and receiving its
reflection, determines point of discontinuity.
156
• Magnetic particle inspection: For small voids & cracks
at or just below the surface of ferromagnetic material.
• Ferrous powder particles accumulated on the disrupted
magnetic field.
• Dye penetration test: Detect invisible surface defect.
• Thin low viscosity & low surface tension liquid
containing suitable dye is applied.
• Penetrated by capillary action in fine cavities pores,
cracks.
• Extra liquid is cleaned & chalk powder is sprinkled over
the surface
• Chalk sucks out the liquid with dye where ever it is
present inside the surface discontinuity. 157
• Question 57.
In order to ram the sand softer on the pattern face and
harder at the back of the mould, which of the following
types of moulding machines is used?
[SSC-JE : 2008]
a. Jolt
b. Sand slinger
c. squeezing
d. Stripper plate

158