Casting?

Casting is a manufacturing process by which a liquid

material such as a molten metal is introduced into a
mould, allowed to solidify within the mould, and then
ejected to make a fabricated part.

Casting is used for making parts of complex shape that

would be difficult or uneconomical to make by other
methods, such as cutting from solid material.
 Sand casting
• A sand casting is a cast part, which is produced by pouring liquid
metal into a mold made of a mixture of silica sand with addition of
clay, moisture and some other additives (green sand) packed
around a pattern in order to form a mold cavity.

• After the molding sand mixture has been packed and compacted
around it, the pattern is withdrawn and molten metal is poured into
the mold cavity which remains.

• After the metal has solidified and cooled, the casting is separated
from the sand mold. The sand castings are easily recognized due its
sand-like texture imparted by the sand mold.
• As the accuracy of the casting is limited by the green
sand making process, there is always some sand
residues on the surface of the castings to be removed.

• It is usually done by shot blasting process, where the

casting surface is exposed to a stream of steel or iron
shots, blasting its surface until the skin of oxides,
silicates and other compounds will be removed.

• The molding sand going back into the sand processing

plant will be remoistured and new additives mixed in.
This means that the molding sand is reusable after
adjusting its composition, replacing the elements lost in
the thermal casting process. The pattern itself may be
reused to produce new sand molds.
Sand molding process
1. The half of the split pattern to form the drag is placed on
a board and surrounded with a moulding flask .

2: This is then filled with sand mixed with a binder.

Care is taken to ensure no voids are included.

3: This 'half mould' is then inverted, the board removed and the
upper half of the split pattern is located accurately on its lower partner.
 4: A parting agent (traditionally French chalk) will often be dusted over the area
where the sand in the drag will contact the sand to be poured into the cope.

5: Provision will be made for the 'runner' and 'riser'. The runner is to allow the molten
steel to enter the mould. The riser is allow the air to escape. In this case exothermic
sleeves are being used to keep the puddle of steel in the runner and riser hot longer
and thus ensure a complete fill as the molten steel cools and thus contracts.

6&7: Sand mixed with a binder is now poured into the flask that forms the cope. The wooden frame on top of the upper
flask is there to increase the depth of sand on the top half of the mould and thus increase the volume
of metal contained within the puddle. Having a good head of molten metal assists in ensuring a complete fill.
8: The two parts of the mould are separated and the pattern is withdrawn by screwing a tool
into the lifting plate. The moulder is seen applying the threaded tool to the lifting plate
between the two dowels. The dowels ensure the two halves of the pattern align accurately.

9: Final preparation of the mould is made before the core is accurately located within
the mould supported on its core prints.

10: A completed core half about to be removed from the core-box .

11: Again using sand mixed with binder the core is prepared. In this case the core is
formed from two halves glued together. The join line of the two halves can be seen in this
photograph.

   12: The core can be seen in place awaiting closure of the mould.                    

13: The two halves of the mould are brought together. A dowel and corresponding
hole at each end of the two parts of the flask ensure the cope and drag align.
 14: Steel of the correct mix is prepared in an electric furnace.

15: Pouring from the furnace to a crucible that will be taken to the mould
by means of an overhead crane

16: The pour from crucible to mould. Note full safety equipment worn by the foundry man.
Molten steel is to be treated with great respect!
  
17: The filled moulds are now left to cool. With a casting  
this size the mould will be opened tomorrow.  
 

 
18. One very nice pair of taper-shank buffers ready for machining before being fitted
to 4566. Coincidentally the pattern makers number the patterns uniquely by using
their initials followed by a sequential number. Gordon Woodruff made these patterns,
hence the GW21appearing on the moulding equipment.
                                      
            
• Patterns
From the design, provided by an engineer or designer, a skilled
pattern maker builds a pattern of the object to be produced, using
wood, metal, or plastic; other materials such as expanded
polystyrene.

The metal to be cast will contract during solidification, and this may be
non-uniform due to uneven cooling. Therefore, the pattern must be
slightly larger than the finished product, a difference known as
contraction allowance. Pattern-makers are able to produce suitable
patterns using 'Contraction rules' (these are sometimes called "shrink
allowance rulers" where the ruled markings are deliberately made to
a larger spacing according to the percentage of extra length needed).

Different scaled rules are used for different metals because different
metals / alloys contract by differing amounts.
 Pouring
• Paths for the entrance of metal, during the pouring
(casting) process into the mold cavity constitute the
runner system and include the sprue, various feeders
which maintain a good metal 'feed' and 'runners', and in-
gates which attach the runner system to the casting
cavity. Gas and steam generated during casting exit
through the permeable sand or via the riser, are added
either in the pattern itself, or as separate pieces.
 Molding box and materials
• A multi-part molding box (known as a casting flask, the top and
bottom halves of which are known respectively as the
cope and drag) is prepared to receive the pattern. Molding boxes
are made in segments that may be latched to each other and to end
closures.

• For a simple object—flat on one side—the lower portion of the box,

closed at the bottom, will be filled with prepared casting sand or
green sand—a slightly moist mixture of sand and clay. The sand is
packed in through a vibratory process called ramming

• The surface of the sand may then be stabilized with a sizing

compound. The pattern is placed on the sand and another molding
box segment is added. Additional sand is rammed over and around
the pattern. Finally a cover is placed on the box and it is turned and
unlatched, so that the halves of the mold may be parted and the
pattern with its sprue and vent patterns removed.
• Additional sizing may be added and any defects
introduced by the removal of the pattern are corrected.
The box is closed again. This forms a "green" mold
which must be dried to receive the hot metal.

• If the mold is not sufficiently dried a steam explosion

can occur that can throw molten metal about. In some
cases, the sand may be oiled instead of moistened,
which makes possible casting without waiting for the
sand to dry. Sand may also be bonded by chemical
binders, such as resins or amine-hardened resins.
 Chills
• To control the solidification and metallurgical structure of
the metal, it is possible to place metal plates—chills— in
the mold.

• The associated rapid local cooling will form a finer-

grained structure and may form a somewhat harder
metal at these locations.

• In ferrous castings the effect is similar to quenching

metals in work.

• In controlling the way a casting freezes it is possible to

prevent internal voids or porosity inside castings
 Cores
• To produce cavities within the casting—such as
for liquid cooling in engine blocks and cylinder
heads—negative forms are used to produce
cores.
• Usually sand-molded, cores are inserted into the
casting box after removal of the pattern.

• Whenever possible, designs are made that avoid

the use of cores, due to the additional set-up
time and thus greater cost.
 Applications
• Valve
 Sand Casting
• With sand casting, probably the most common method, ordinary
sand is used as the mold material.

• A two-piece mold is formed by packing sand around a pattern that

has the shape of the intended casting. Furthermore, a gating system
is usually incorporated into the mold to expedite the flow of molten
metal into the cavity and to minimize internal casting defects.

• Sand-cast parts include automotive cylinder blocks, fire hydrants,

and large pipe fittings
Sand molding process
 Die Casting
• In die casting, the liquid metal is forced into a mold under
pressure and at a relatively high velocity, and allowed to
solidify with the pressure maintained.

• A two piece permanent steel mold or die is employed;

when clamped together, the two pieces form the desired
shape. When complete solidification has been achieved,
the die pieces are opened and the cast piece is ejected.
• Rapid casting rates are possible, making this an
inexpensive method; furthermore, a single set of dies
may be used for thousands of castings.

• However, this technique lends itself only to relatively

small pieces and to alloys of zinc, aluminum, and
magnesium, which have low melting temperatures.
 Investment Casting
• For investment (sometimes called lost-wax) casting, the pattern is
made from a wax or plastic that has a low melting temperature.

• Around the pattern is poured a fluid slurry, which sets up to form a

solid mold or investment; plaster of paris is usually
used.

• The mold is then heated, such that the pattern melts and is burned
out, leaving behind a mold cavity having the desired shape.
• This technique is employed when high dimensional
accuracy, reproduction of fine detail, and an excellent
finish are required—for example, in jewelry and dental
crowns and inlays. Also, blades for gas turbines and jet
engine impellers are investment cast.