The Fundamentals of Metal

Casting
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MATA KULIAH PROSES PRODUKSI

JURUSAN TEKNIK INDUSTRI ITENAS
SEMESTER GANJIL 2008/2009
 1. Definition
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Casting is process in which molten metal flows by

gravity or other force into a mold where it solidifies
in the shape of the mold cavity.
The principle of casting seems simple: melt the
metal, pour it into mold and let it freeze.
 2. Casting ingots & Casting of the shape
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Casting ingots  associated with the primary metals

industries, simple in shape and intended for
subsequent reshaping by processes such rolling or
forging.
Shape casting  involves the production of more
complex geometries that are much closer to the final
desired shape of the part or product.
 3. Casting capabilities and advantages
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Casting can be used to create complex part

geometries, including both external and internal
shape.
Some casting process are capable of producing parts
to net shape. Other casting processes are near net
shape.
Casting can be used to produce very large parts.
The casting process can be performed on any metal
that can be heated to the liquid state.
Some casting methods are quite suited to mass
production.
 4. Casting disadvantages
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Limitations on mechanical properties.

Porosity
Poor dimensional accuracy and surface finish for
some casting process
Safety hazard to human when processing hot molten
metals.
Environmental problems.
 5. Mold
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The mold contains a cavity whose geometry

determine the shape of the cast part.
The actual size and shape of the cavity must be
designed slightly oversized to allow for shrinkage
that occurs in the metal during solidification and
cooling.
Molds are made of a variety of materials, including
sand, plaster, ceramic, and metal.
 5.1 Two forms of mold
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(a) open mold (b) closed mold

5.2 Casting process categories (according to type
of mold used)
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An expandable mold  The mold in which the

molten metal solidifies must be destroyed in order to
remove the casting. These mold are made out of
sand, plaster, and similar materials, whose form is
maintained by using binders of various kind.
A permanent mold  Can be used over and over to
produce many castings. It is made of metals that can
withstand the high temperature of the casting
process
 6. Sand Casting Molds
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Cope?
Drag?
A Flask?
The parting line?
A Pattern?
A core?
The gating system?
A Downsprue?
A runner?
 7. Heating
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Heating furnaces is used to heat the metal to a

molten temperature sufficient for casting.
The heat energy required is the sum of (1) heat to
raise the temperature to the melting point, (2) heat a
fusion to convert it from solid to liquid, and (3) heat
to raise the molten metal to the desired temperature
for pouring.
7. Heating (continue)
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 8. Pouring The Molten Metal
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After heating, the metal is ready for pouring.

Introduction of molten metal into the mold,
including its flow through the gating system and into
the cavity, is a critical step in the casting process.
This step to be successful, the metal must flow into
all region of the mold, including most important the
main cavity, before solidifying.
 8. Pouring The Molten Metal (continue)
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Factors affecting the pouring operation include:

 The pouring temperature  the temperature of the molten
metal as it is introduced into the mold.
 Pouring rate  volumetric rate which the molten metal is
poured into the mold. To slow  the metal will chill and freeze
before filling the cavity. To excessive  turbulence.
 Turbulence  characterized by erratic variation in the
magnitude and direction of the velocity throughout the fluid.
The flow is agitated and irregular rather than smooth and
streamline, as in laminar flow.
 9. Solidification and Cooling
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Solidification involves the transformation of the

molten back into the solid state.
Solidification pure metals
 9. Solidification and Cooling (continue)
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Phase diagram for alloy system

 9. Solidification and Cooling (continue)
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Eutectic Alloys
 10. Solidification Time
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Total. Solidification Time  time required for the

casting to solidify after pouring.
11. Shrinkage
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 12. Directional Solidification
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Directional solidification is used to describe this

aspect of the freezing process and the methods by
which is controlled.
 13. Riser Design
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Riser Design is used in a sand casting mold to feed

liquid metal to the casting during freezing in order to
compensate for solidification shrinkage
Thank You

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