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LECTURE BY SIR ALI IRTAZA

Production Engineering
4- CASTING
Casting 2

LECTURE BY SIR ALI IRTAZA

 Casting is a process in which molten metal flows by gravity or other force into a
mold where it solidifies in the shape of the mold cavity.
 It is one of the oldest shaping processes, dating back 6000 years.
 Casting includes both the casting of ingots and the casting of shapes. The term
ingot is usually associated with the primary metals industries.
 LECTURE BY SIR ALI IRTAZA
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Basic Steps of Casting.
Why Use Casting Process? 4

LECTURE BY SIR ALI IRTAZA

 Casting can be used to create complex part geometries, including both external
and internal shapes.
 Some casting processes are capable of producing parts to net shape. No further
manufacturing operations are required to achieve the required geometry and
dimensions of the parts. Other casting processes are near net shape, for which
some additional shape processing is required (usually machining) in order to
achieve accurate dimensions and details.
 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.
Disadvantages of Casting Process 5

LECTURE BY SIR ALI IRTAZA

 These include limitations on mechanical properties,
 Porosity,
 Poor dimensional accuracy
 Poor Surface finish for some casting processes,
 safety hazards to humans when processing hot molten metals,
 Environmental problems.
Casting Technology 6

LECTURE BY SIR ALI IRTAZA

 As a production process, casting is usually carried out in a foundry.
 A foundry is a factory equipped for making molds, melting and handling metal in
molten form, performing the casting process, and cleaning the finished casting.
 The workers who perform the casting operations in these factories are called
foundrymen.
CASTING PROCESSES 7

LECTURE BY SIR ALI IRTAZA

 The mold contains a cavity whose geometry determines the shape of the cast part.
 The actual size and shape of the cavity must be 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.
 The metal is first heated to a temperature high enough to completely transform it
into a liquid state. It is then poured.
Mold 8

LECTURE BY SIR ALI IRTAZA

 It contains a cavity whose geometry determines the shape of the casting.
Types of Mold 9

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 Open Mold
 Close Mold
Mold–Open Mold 10

LECTURE BY SIR ALI IRTAZA

 In open mold, raw material is exposed to air as they cure or harden.
 In case of metals, the liquid metal is poured and completely filled in an open
cavity.
 It utilizes different processes. For example: hand lay-up technique, casting,
filament winding, etc.
Mold–Closed Mold 11

LECTURE BY SIR ALI IRTAZA

 In closed mold, raw material is not exposed to air as they cure or harden.
 In case of metals, the liquid metal is poured through a passage way called ‘gating
system’ to flow into the moldcavity.
 It is comprised of two parts:
 a) Cope
 b) Drag
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LECTURE BY SIR ALI IRTAZA

Mold–Closed Mold
Categories of Molds. 13

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 Expendable mold casting
 Permanent mold casting
An expendable mold 14

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 An expendable mold means that the mold in which the molten metal solidifies
must be destroyed in order to remove the casting.
 These molds are made out of sand, plaster, or similar materials, whose form is
maintained by using binders of various kinds.
 Sand casting is the most prominent example of the expendable mold processes.
 In sand casting, the liquid metal is poured into a mold mad of sand. After the
metal hardens, the mold must be sacrificed in order to recover the casting.
A permanent mold 15

LECTURE BY SIR ALI IRTAZA

 A permanent mold is one that can be used over and over to produce many
castings.
 It is made of metal (or, less commonly, a ceramic refractory material) that can
withstand the high temperatures of the casting operation.
 In permanent mold casting, the mold consists of two (or more) sections that can
be opened to permit removal of the finished part.
 Die casting is the most familiar process in this group
Melting 16

LECTURE BY SIR ALI IRTAZA

 The required to melt the metal is the sum of:
a) Heat to raise the temperature to melting point.
b) Heat of fusion to convert from solid to liquid.
c) Heat to raise the desired temperature for pouring
Pouring 17

LECTURE BY SIR ALI IRTAZA

 Introduce the molten metal into the mold.
 Provision should be made for the escape of all air and gases.
 Molten metal must be free to fill the cavity.
 Molten metal must flow into all regions of moldespecially moldcavity before
solidification.
 Following factors affect the pouring the pouring operation:
a) Pouring temperature
b) Pouring rate
c) Turbulence
Solidification & Cooling 18

LECTURE BY SIR ALI IRTAZA

 Casting is a solidification process. Therefore, should be properly designed and
controlled.
 Most of the material properties are set during solidification therefore, castings
should be designed so that solidification should occur without producing porosity.
 Solidification involves the transformation of the molten metal back into the solid
state. The solidification process differs depending on whether the metal is a pure
element or an alloy.
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LECTURE BY SIR ALI IRTAZA

Pure Metals
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Most Alloys
SHRINKAGE 21

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 When a molten metal (pure metal or alloy) enters the mold cavity, it undergoes a
noticeable volumetric contraction.
 This volumetric contraction is called ‘solidification shrinkage.’
 It has three stages:
a) Shrinkage of liquid
b) Solidification shrinkage
c) Solid metal contraction
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SHRINKAGE
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SHRINKAGE
DIRECTIONAL SOLIDIFICATION 24

LECTURE BY SIR ALI IRTAZA

 The term directional solidification is used to describe this aspect of the freezing
process and the methods by which it is controlled.
 The desired directional solidification is achieved by observing in the design of the
casting itself, its orientation within the mold, and the design of the riser
 chills—internal or external heat sinks that cause rapid freezing in certain regions
of the casting. system that feeds it.
RISER DESIGN 25

LECTURE BY SIR ALI IRTAZA

 Riser is used in a sand-casting mold to feed liquid metal to the casting during
freezing in order to compensate for solidification shrinkage.
 To function, the riser must remain molten until after the casting solidifies.
Mold Removal 26

LECTURE BY SIR ALI IRTAZA

 Part should be easy to remove from the mold.
 Expendable molds have no difficulty as molds are destroyed after each casting.
 Permanent molds have problem when complex parts are casted
Cleaning, Finishing & Inspection 27

LECTURE BY SIR ALI IRTAZA

 Cleaning is required to remove extra material attached with the casting.
 This extra material comes from the parts of gating system, mold parting lines, etc.
 This extra material must be removed the finished casting.
 Following additional steps are usually required after removal of casting from mold:
a) Trimming
b) Core Removal
c) Surface Cleaning
d) Inspection
e) Repair (if required)
f) Heat Treatment