Chapter four

4.special casting processes

contents to be included
 Introduction
 expandable mold casting like
 Sand mold ,
 shell mold
 expandable pattern
 plaster molding ,
 ceramic molding and
 investment casting processes
 permanent mold casting processes
 Die casting,
 Centrifugal casting
 4.1 Introduction
 When the mold is used for single casting, it made of sand and
known as expendable mold.
 When the mold is used repeatedly for number of castings and is
made of metal or graphite are called permanent Mould.
Metals processed by casting

 Sand casting – 60%

 Investment casting – 7%
 Die casting – 9%
 Permanent mold casting – 11%
 Centrifugal casting – 7%
 Shell mold casting – 6%
4.2 Expendable Mold: mold is sacrificed to remove part .
Permanent Pattern: a number of processes use
permanent patterns. Of these processes, however,
green sand molding is the most prevalent
E.g. Sand Casting
Expendable Pattern: use polystyrene patterns (lost
foam casting and Replicast process) or wax patterns.
Plaster molding ,
Ceramic molding
 SHELL MOLD CASTING
 Shell mold casting process is recent invention in casting techniques
for mass production and smooth surface finish. It was originated in
Germany during Second World War.
 It is also called as Carning or C process. It consists of making a
mold that possesses two or more thin shells (shell line parts, which
are moderately hard and smooth with a texture consisting of
thermosetting resin bonded sands.
 The shells are 0.3 to 0.6 mm thick and can be handled and stored.
Shell molds are made so that machining parts fit together-easily.
 They are held using clamps or adhesive and metal is poured either in
a vertical or horizontal position.
They are supported using rocks or mass of bulky permeable
material.
Thermosetting resin, dry powder and sand are mixed
thoroughly in a Muller.
It is a Casting process in which the mold is a thin shell of
sand held together by thermosetting resin binder.
The sand is mixed with a thermosetting resin is allowed to
come in contact with a heated metal pattern
  Complete shell molding casting processes is carried in four stages
as shown in Fig below.
1. A metal pattern is heated and placed over a box containing sand mixed
with thermosetting resin.

 The pattern is heated first and silicon grease is then sprayed on the
heated metal pattern for easy separation.
 The pattern is heated to 205 to 230°C and covered with resin
bounded sand.
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. Hard outer covering

3. Box is repositioned so loose uncured

particles drop away

4.Sand shell is heated in oven for several

minutes to complete curing
shell mold is stripped from pattern
(5) shell mold is stripped from pattern

(6) Two halves of the shell mold are assembled,

supported by sand or metal shot in a box, and
pouring is accomplished

(7) Finished casting with Sprue removed

Advantages and Disadvantages of Shell Molding:
Advantages Shell Molding:
 High suitable for thin sections like petrol engine cylinder.
 Excellent surface finish.
 Good dimensional accuracy of order of 0.002 to 0.003 mm.
 Negligible machining and cleaning cost.
 Occupies less floor space.
 Skill-ness required is less.
 Moulds formed by this process can be stored until required.
 Better quality of casting assured.
 Mass production.
 It allows for greater detail and less draft.
 Disadvantages Shell Molding:

 Higher pattern cost.

 Higher resin cost.
 Not economical for small runs.
 Dust-extraction problem.
 Complicated jobs and jobs of various sizes cannot be easily shell
molded.
 Specialized equipment is required.
 Resin binder is an expensive material.
 Limited for small size.
Applications
 Suitable for production of casting made up of alloys of Al,
Cu and ferrous metals
 Bushing
 Valves bodies
 Rocker arms
 Bearing caps
 Brackets
 Gears
 4.3 Plaster Mold Process

 Plaster mold casting, also called rubber plaster molding (RPM), is a

method of producing aluminum or zinc castings by pouring liquid
metal into plaster (gypsum) molds.
 The mould material in plaster molding is gypsum or plaster of
paris.
 To this plaster of Paris, additives like talc, fibers, asbestos, silica
flour etc. are added in order to control the contraction
characteristics of the Mould as well as the settling time.
 The plaster of paris is used in the form of a slurry(a mixture of
water and solid)
 The consistency of the slurry is defined as
the pounds of water per 100 pounds of
plaster mixture and This plaster slurry is
poured over a metallic pattern confined in a
flask as shown below.
 The pattern is usually made of brass
and it is generally in the form of half
portion of job to be cast and is
attached firmly on a match plate
which forms the bottom of the
molding flask.
 Wood pattern are not used because the water in the plaster raises
the grains on them and makes them difficult to be withdrawn.

 Some parting or release agent is needed for easy withdrawal of the

pattern from the mold.
 As the flask is filled with the slurry, it is vibrated so as to bubble out
any air entrapped in the slurry and to ensure that the mould is
completely filled up. The plaster material is allowed to set.
 Finally when the plaster is set properly the pattern is then withdrawn
by separating the same, from the plaster by blowing compressed air
through the holes in the patterns leading to the parting surface
between the pattern and the plaster mold.
 The plaster mold thus produced is dried in an oven to a temperature
range between 200-700 degree centigrade and cooled in the oven
itself.
 In the above manner two halves of a Mould are prepared and are
joined together to form the proper cavity.
 The necessary sprue, runner etc. are cut before joining the two parts.
Advantages
 In plaster molding, very good surface finish is obtained and machining cost
is also reduced.
 Slow and uniform rate of cooling of the casting is achieved because of low
thermal conductivity of plaster and possibility of stress concentration is
reduced.
 Metal shrinkage with accurate control is feasible and thereby warping and
distortion of thin sections can be avoided in the plaster molding.
Limitations
 There is evolution of steam during metal pouring if the plaster mold is not
dried at higher temperatures avoid this, the plaster mold may be dehydrated
at high temperatures, but the strength of the mould decreases with
dehydration.
 The permeability of the plaster mold is low. This may be to a certain extent
but it can be increased by removing the bubbles as the plaster slurry is
mixed in a mechanical mixer.
 Ceramic Mold Casting

 The manufacturing process of ceramic mold casting is like the process of

plaster mold casting but can cast materials at much higher temperatures.
 Instead of using plaster to create the mold for the metal casting, ceramic
casting uses refractory ceramics for a mold material.
 In industry parts such as machining cutters, dies for metalworking,
metal molds, and impellers may be manufactured by this process.
The Process

 The first step in manufacture by ceramic mold casting is to combine

the material for the mold.
The ceramic molding process can be summarized in 7 steps:
Step 1: The pattern is designed with the materials already mentioned
(plastic, wood, metal, etc.).
Step 2: The mix is injected into a binder.
Step 3: Part of some refractory ceramic powder is taken out, according
to what is needed.
Step 4: To the binder, there is added a special gelling, in order to be
mixed.
Step 5: The slurry is put into the pattern.
Step 6: The slurry is heated to a high temperature, depending on what
is required.
Step 7: The slurry is allowed to cool and the process is done.
 A mixture of fine grain zircon (ZrSiO4), aluminum oxide. fused
silica, bonding agents, and water, creates a ceramic slurry.(a mixture
of water and solid
 This slurry is poured over the casting pattern and let set.

 The pattern is then removed and the mold is left to dry The mold is
then fired.
 The firing will burn off any unwanted material and make the mold
hardened and rigid.
 The mold may also need to be baked in a furnace as well. The firing of the mold
produces a network of microscopic cracks in the mold material.
 These cracks give the ceramic mold both good permeability and collapsibility for
the metal casting process.

 Once prepared, the two halves of the mold are assembled for the
pouring of the metal casting.
 The two halves,(cope and drag section), may be backed up with
fireclay material for additional mold strength.
 Often in manufacturing industry, the ceramic mold
will be preheated prior to pouring the molten metal
 The metal casting is poured, and let solidify.
 In ceramic mold casting, like in other expendable
mold processes, the ceramic mold is destroyed in the
removal of the metal casting

Properties and Considerations Of Manufacturing By Ceramic Mold Casting

 Manufacturing by ceramic mold casting is similar to plaster mold casting in

that it can produce parts with thin sections, excellent surface finish, and
high dimensional accuracy.
 Manufacturing tolerances between .002 and .010 inches are possible with
this process.
 To be able to cast parts with high dimensional accuracy eliminates the need
for machining, and the scrap that would be produced by machining.
 Therefore precision metal casting processes like this are efficient to cast
precious metals, or materials that would be difficult to machine.
 Unlike the mold material in the plaster metal casting process, the refractory
mold material in ceramic casting can withstand extremely elevated
temperatures.
 Due to this heat tolerance, the ceramic casting process can be used to
manufacture ferrous and other high melting point metal casting
materials.
 Stainless steels and tool steels can be cast with this process.
.Ceramic mold casting is relatively expensive.
. The long preparation time of the mold makes manufacturing
production rates for this process slow.

 Unlike in plaster mold casting, the ceramic mold has excellent

permeability due to the microcrazing, (production of microscopic cracks),
that occurs in the firing of the ceramic mold.
 Expanded Polystyrene Process

 Uses a mold of sand packed around a polystyrene foam pattern

which vaporizes when molten metal is poured into mold
• Other names: lost‑foam process, lost pattern process,
evaporative‑foam process, and full‑mold process
• Polystyrene foam pattern includes sprue, risers, gating system, and
internal cores (if needed)
• Mold does not have to be opened into cope and drag sections
 Steps in Expanded Polystyrene Process

 Polystyrene foam pattern is coated with

refractory compound
 Foam pattern is placed in mold box, and sand is
compacted around the pattern
 Molten metal is poured into the portion of the
pattern that forms the pouring cup and sprue
• As the metal enters the mold, the polystyrene
foam is vaporized ahead of the advancing liquid,
thus filling the mold cavity
 Advantages and Disadvantages of Expanded
Polystyrene Process:
 Advantages of expanded polystyrene process:

– Pattern need not be removed from the mold

– Simplifies and speeds mold‑making, because two mold halves
are not required as in a conventional green‑sand mold
 Disadvantages:
– A new pattern is needed for every casting

– Economic justification of the process is highly dependent on

cost of producing patterns
Applications:
 Mass production of castings for automobile engines
 Automated and integrated manufacturing systems are used to
1. Mold the polystyrene foam patterns and then
2. Feed them to the downstream casting operation
 INVESTMENT CASTING

 In Investment Casting, a ceramic slurry is applied around a

disposable pattern, usually wax, and allowed to harden to form a
disposable casting mold.
 The term disposable means that the pattern is destroyed during
its removal from the mold and that the mold is destroyed to
recover the casting.
 Related processes, in which ceramic slurries are poured against
permanent patterns to make cope and drag molds, are covered
in the articles "Plaster Molding" and "Ceramic Molding" in this
Volume.
 A pattern made of wax is coated with a refractory material to make
the mold, after which wax is melted away prior to pouring molten
metal
 "Investment" comes from a less familiar definition of "invest" - "to
cover completely," which refers to coating of refractory material
around wax pattern .
 It is a precision casting process
 Capable of producing castings of high accuracy and intricate detail

 There are two distinct processes for making investment casting

molds: the solid investment (solid mold) process and the
ceramic shell process.
 The ceramic shell process has become the predominant
technique for engineering applications, displacing the solid
investment process.

 Pattern Materials :Pattern materials for investment casting can be

loosely grouped into waxes and plastics.
 Waxes are more commonly used.
 Plastic patterns (usually polystyrene) are frequently used in
conjunction with relatively thin ceramic shell molds in a
Process known as Replicast.
Waxes : Wax is the preferred base material for most investment
casting patterns, but blends containing only waxes are seldom
used.
Waxes are usually modified to improve their properties through
the addition of such materials as resins, plastics, fillers,
plasticizers, antioxidants, and dyes. because their properties tend to
be complementary.

 The most widely used waxes for patterns are paraffin's and
microcrystalline waxes. These two are often used in combination
 Steps in Investment Casting

(1) Wax patterns are produced

(2) Several patterns are attached
to a Sprue to form a pattern tree

(3) Pattern tree is coated with a thin

layer of refractory material to withstand
high temperatures
(4) Full mold is formed by covering the
coated tree with sufficient refractory
material to make it rigid.
5) Mold is held in an inverted position and
heated to melt the wax and permit it to drip out
of the cavity.

(6) Mold is preheated to a high

temperature, the molten metal is
poured, and it solidifies.

(7) Mold is broken away from the

finished casting and the parts are
separated from the sprue.
  Advantages:
 Parts of great complexity and intricacy can be cast
 Close dimensional control and good surface finish

 Wax can usually be recovered for reuse

 This is a net shape process
 Additional machining is not normally required

 Disadvantages:
 Many processing steps are required
 Relatively expensive process

One‑piece compressor stator with 108 separate airfoils

made by investment casting
 4.4 Permanent Mold Process
 In permanent mold casting, the mold is reused many times
The processes include:
 Basic permanent mold casting
 Die casting
 Centrifugal casting
 The Basic Permanent Mold Process

 Uses a metal mold constructed of two sections designed for easy,

precise opening and closing.
• Molds used for casting lower melting-point alloys (Al, Cu, Brass) are
commonly made of steel or cast iron
• Molds used for casting steel must be made of refractory material,
due to the very high pouring temperatures
 Steps in Permanent Mold Casting

(1) Mold is preheated and coated for

lubrication and heat dissipation.

(2) Cores (if any are used) are inserted

and mold is closed.

(3) Molten metal is poured into the

mold, where it solidifies.
 Advantages and Limitations
• Advantages of permanent mold casting:

– Good dimensional control and surface finish.

– Very economical for mass production.

– Rapid solidification caused by metal mold results in a finer grain

structure, so castings are stronger .
• Limitations:
– Generally limited to metals of lower melting point .

– Simpler part geometries compared to sand casting and Complex part

geometries because of need to open the mold.

– High cost of mold .

– Not suitable for low-volume production.
 Applications and Metals for Permanent Mold Casting

• Due to high mold cost, process is best suited to high volume

production and can be automated accordingly
• Typical parts: automotive pistons, pump bodies, and certain
castings for aircraft and missiles
• Metals commonly cast: aluminum, magnesium, copper‑base alloys,
and cast iron
– Unsuited to steels because of very high pouring temperatures
 Die Casting
 Die casting is a manufacturing process for producing metal parts by
forcing molten metal under high pressure into a die cavity.
 Die or mold cavities are created with hardened tool steel that have
been previously machined to the net shape or near net shape of the
die cast parts.
• This process allows products to be made with high degree of
accuracy and repeatability.
• The die casting process also produce fine details such as textured
surfaces or names without requiring further processing.
 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 (7-35MPa) to force metal into die cavity is
what distinguishes this from other permanent mold processes
 The die casting process usually produce parts using primarily non-
ferrous metals, such as zinc, copper, aluminum and magnesium.
 die casting machines
 Designed to hold and accurately close two mold halves and keep
them closed while liquid metal is forced into cavity
 The die casting process can be further divided into two different
categories based on the type of machine used.
 Hot Chamber Die Casting
 Cold Chamber Die Casting
 Hot Chamber Die Casting is the process where the injection system is
immersed in pool of molten metal hence the name.  
 The furnace is attached to the machine via a feeding system called a
gooseneck.
Injection pressure: 7-35MPa

Hot‑chamber die casting cycle:

(1) As the cycle begins the piston will
Hot‑chamber die casting machine
retracts, which allows the molten
metal to fill the “gooseneck” from a
port in the injection cylinder, with die
closed and plunger withdrawn, molten
metal flows into the chamber
(2) As the plunger move downwards, it  seals the
port and forces the molten metal through the
gooseneck and nozzle into the die, maintaining
pressure during cooling and solidification.

(3) Once the metal solidifies, the plunger will

pull upwards.  Afterwards, the die will open and
the part is ejected. die.pptx
The advantage of this process is
 short cycle time as it does not require metal to be transported
from a separate furnace.  .
 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
Cold Chamber Die Casting: Molten
metal is poured into unheated
chamber from external melting
container, and a piston injects
metal under high pressure into die
cavity
high melting point metals can be
casted could‑chamber die casting machine

 It uses a ladle to transport the molten metal from the holding

furnace into the unheated shot chamber or injection cylinder.
 This metal is then shot into the die by using a hydraulic piston.
 Casting metals: aluminum, brass, and magnesium alloys
 High production but not usually as fast as hot‑chamber machines
because of pouring step .
 Cold‑Chamber Die Casting Cycle

(1) With die closed and ram

withdrawn, molten metal is poured

into the chamber

(2) Ram forces metal to flow into
die, maintaining pressure during
cooling and solidification.

 high pressure (14-140MPa) into die

cavity
(3) Ram is withdrawn, die is opened,
and part is ejected
The main disadvantage of this process is that it is relatively slower compared
to the Hot Chamber Die Casting  process.  However, this process is primarily
used for manufacturing aluminum parts as molten aluminum alloys have a
tendency to attack and erode the metal cylinders, plungers and dies greatly
shortening their tool life.
Other die casting processes
The Low-Pressure Die Casting Process
Low-pressure die casting is a process best suited for aluminum components
that are symmetric around an axis of rotation. Vehicle wheels, for example,
are often fabricated through low-pressure die casting. In this type of process,
the mold is situated vertically above the molten metal bath and connected via
a riser tube. When the chamber is pressurized (usually between 20 and
100kPa), the metal is pulled upward and into the mold.
The Vacuum Die Casting Process
 Vacuum pressure casting (VPC) is a relatively new die casting
process that delivers enhanced strength and minimal porosity.
 This process is similar to low-pressure die casting, except the
locations of the die cast mold and molten metal bath are reversed.
 The cylinder chamber can become a vacuum, which forces the
molten metal into the mold cavity.
 This design reduces turbulence and limits the amount of gas
inclusions.
 Vacuum die casting is especially beneficial in applications destined
for post-casting heat treatment. 
Steps in vacuum molding:
1) a thin sheet of preheated plastic is drawn over a match-plate or
cope-and-drag pattern by vacuum.
the pattern has small vent holes to facilitate vacuum forming;
(2) a specially designed flask is placed over the pattern plate and
filled with sand, and a Sprue and pouring cup are formed in the sand;
(3) another thin plastic sheet is placed over the flask, and a vacuum is
drawn that causes the sand grains to be held together, forming a grid
mold.
(4) the vacuum on the mold pattern is released to permit the pattern
to be stripped from the mold;.
(5) this mold is assembled with its matching half to form the cope
and drag and with vacuum maintained on both halves, pouring ¡s
accomplished.
The plastic sheet quickly burns away on contacting the molten
metal. After solidification, nearly all of the sand can be recovered for
reuse.
 Squeeze Casting
 Combination of casting and forging in which a molten metal is
poured into a preheated lower die, and the upper die is closed to
create the mold cavity after solidification begins.
 Squeeze casting was created as a workable solution for casting
metals and alloys with low fluidity.
 In this process, the molten metal fills up an open die, which then
squeezes closed, forcing the metal into the recessed portions of the
molding.
 The squeeze casting process delivers extremely dense products
and is a complementary process to subsequent heat-treating.
 The process is most often associated with molten aluminum, and is
used in applications that call for fiber reinforcement.
 Differs from usual closed-mold casting processes in which die
halves are closed before introduction of the molten metal.
 Compared to conventional forging, pressures are less and finer
surface details can be achieved
 Molds for Die Casting

 Usually made of tool steel, mold steel, or maraging steel

 Tungsten and molybdenum (good refractory qualities) used to die
cast steel and cast iron
 Ejector pins required to remove part from die when it opens.
 Lubricants must be sprayed onto cavity surfaces to prevent
sticking .
 Advantages and Limitations of Die Casting:
• Advantages:
– Economical for large production quantities
– Good accuracy and surface finish
– Thin sections possible .

– Rapid cooling means small grain size and good strength in casting.

• Disadvantages:
– Generally limited to metals with low melting points.

– Part geometry must allow removal from die so very complex parts can
not be casted.
– Flash and metal in vent holes need to be cleaned after ejection of
part.
 Centrifugal casting
 A family of casting processes in which the mold is rotated at high
speed so centrifugal force distributes molten metal to outer regions
of die cavity .
 The manufacturing process of centrifugal casting is a metal casting
technique, that uses the forces generated by centripetal acceleration
to distribute the molten material in the Mould.
 Cast parts manufactured in industry include various pipes and tubes;
such as sewage pipe& gas pipes; and water supply lines also
bushings, rings, the liner for engine cylinders, brake drums, and
street lamp posts
Materials
Typical materials that can be cast with this process are iron, steel,
stainless steels, glass, and alloys of aluminum, copper and nickel.
Two materials can be cast together by introducing a second material
during the process. The group includes:
 True centrifugal casting
 Semi-centrifugal casting
 Centrifuge casting
True Centrifugal Casting
 The molds used in true centrifugal casting manufacture are round, and are
typically made of iron, steel, or graphite.
 Some sort of refractory lining or sand may be used for the inner surface of

the mold.
 In this process molten metal is poured into a rotating mold to
produce a tubular part which is accomplished by the use of rollers.
 In some operations, mold rotation commences after pouring rather
than before.
 Rotational axes can be either horizontal or vertical
 Molds for smaller parts may be rotated about a vertical axis.
However, most times in true centrifugal casting manufacture the
mold will be rotated about a horizontal axis.
 The molten material for the cast part is introduced to the mold from an
external source, usually by means of some pouring basin.
 The liquid metal flows down into the mold. Once inside the cavity, the
centripetal forces from the spinning mold force the molten material to the
outer wall.
 Molten material for the casting may be poured into a spinning mold or the
rotation of the mold may begin after pouring has occurred .
 It can be seen that forces will be greater in the regions further away
from the center of the axis of rotation.
 The greater forces towards the rim will cause the regions of the
metal casting nearer the outer surface to have a higher density than
the sections located nearer the inner surface.
 Thickness of the cast part can be determined by the amount of
material poured.
 Outside shape of casting can be round, octagonal, hexagonal, etc ,
but inside shape is (theoretically) perfectly round, due to radially
symmetric forces .
 Parts: pipes, tubes, bushings, and rings.
 Semi centrifugal Casting
 Semi centrifugal casting manufacture is a variation of true centrifugal
casting.
 The main difference is that in semi centrifugal casting the mold is
filled completely with molten metal, which is supplied to the casting
through a central sprue.
 Castings manufactured by this process will possess rotational
symmetry.
 Much of the details of the manufacturing process of semi centrifugal
casting are the same as those of true centrifugal casting.
 Parts manufactured in industry using this metal casting process
include such things as pulleys; and wheels for tracked vehicles.
 The Process
 In semi-centrifugal casting manufacture a permanent mold may be
employed & However, often industrial manufacturing processes will utilize
an expendable sand mold. This enables the casting of parts from high
temperature materials .

The molten material for the metal

casting is poured into a pouring basin
and is distributed through a central
sprue to the areas of the mold. The
forces generated by the rotation of the
mold ensure the distribution of molten
material to all regions of the casting.

Semi centrifugal casting for mfg of a wheel

 When manufacturing by semi-centrifugal casting, the centripetal
acceleration generated on the mass of molten metal by a rotating
mold is the force that acts to fill the casting with this molten
metal.
 This is also the force that continues to act on the material as the
casting solidifies.
 The main thing to remember about centripetal forces is that the
force will push in a direction that is directly away from the center
of the axis of rotation
 It can be seen that during the semi centrifugal manufacturing
process, the material in the outer regions of the casting, (further
from the center of the axis of rotation), is subject to greater forces
than the material in the inner regions.
Axes of parts and rotational axis does
not match exactly Often used on
parts in which center of casting is
machined away, thus eliminating the
portion where quality is lowest
Examples: wheels and pulleys

 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
 Centrifuge Casting
 the main principles that govern centrifuge casting are the same for all centrifugal
casting processes.
 Centrifuge casting is different in that castings manufactured by the
centrifuge casting process need not have rotational symmetry.
 With centrifuge casting metal castings of desired shapes can be manufactured
with all the distinct benefits of castings produced by a centrifugal casting
process.

 The Process
In centrifuge casting manufacture, molds employed to produce the
desired castings are arranged around a central Sprue.
 These molds contain all the necessary geometry for the cast part, as
well as the gating system.
 Runners travel from the central Sprue to the mold entrances.
 During the pouring phase of
centrifuge casting manufacture,
molten material is introduced into the
central sprue.
 The entire system is rotated about an
axis with the central sprue at the
center of rotation.

 ‘When an object is rotated, forces are produced that act directly away from the
center of the axis of rotation.
 The utilization of the forces of centripetal acceleration which act to push material
away from the center of rotation is the trademark characteristic of all the
manufacturing processes of centrifugal casting.
 Centripetal force is not only utilized to distribute molten material through a mold,
but to help control the material properties of a cast part.
 In centrifuge casting manufacture, the molten material to produce the casting is
poured into the central sprue. Centripetal forces from the rotating apparatus push
this material outward from the center, through the runners and into the molds.
When the correct amount of molten metal to manufacture the casting
is poured and distributed completely into the molds, the apparatus will
continue to rotate as solidification is occurring.
 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
Comparison of Casting Processes
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