CASTING PROCESSES

Submitted by: Submitted to:

K. ASHWIN SHRINIVAS Mr. Abdul Sadiq
2ND Year Asst. Lecturer
IIAE Dehradun IIAE Dehradun

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 TOPICS
• INTRODUCTION

• VACCUM DIE CASTING

•LOW PRESSURE DIE CASTING

• SQUEEZE CASTING

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 INTRODUCTION(1/2)
•What is casting process?
Casting is a manufacturing process which involves the
use of molten material.
This molten material is then poured into a mould cavity
that takes the form of the finished part.
The molten material then cools until it solidifies into the
desired shape.
Fig.1 https://www.thomasnet.c
om/articles/custom-manu
facturing-fabricating/types
-of-casting-processes/

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 INTRODUCTION(2/2)
3 Types of casting which are included in this presentat-
ion are:

• Vacuum Die Casting

• Low Pressure Die Casting
• Squeeze Casting

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 VACUUM DIE CASTING()
What is Die Casting?

Fig.2 Die Casting https://www.substech.com/dokuwiki/doku.php?i

d=die_casting

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 VACUUM DIE CASTING(1/3)
•The major problem with die casting is the air left in the
cavity when the die is closed. Since the air cannot escape
it will end up inside the casting.

•This air bubbles causes damage to the dimensions and

affects the surface finish.

•This problem is solved by evacuating the air from the die

before the metal is injected, thereby the metal enters
much faster into the die and decreases the fill time.

•This process is known as Vacuum die Casting.

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VACUUM DIE CASTING(2/3)

Fig.3 Vacuum die casting https://www.iqsdirectory.com/articl

es/die-casting/aluminum-casting.ht
ml
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 VACUUM DIE CASTING(3/3)

ADVANTAGES:
• Low cost
• Produce large parts
• Repeatability.

DISADVANTAGES:
•Molds and tooling parts needs to be regularly
Maintained.
• Only one part/product can be made at a time
• Intricate details can’t be made.

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 LOW PRESSURE DIE CASTING(1/3)
•This process is particularly used to cast Al and Mg alloys

•In this process, permanent mould is placed over the

furnace containing the molten material.

•Then compressed gas is used at moderate pressure to

force the molten material to rise slowly through the
riser tube that is connected to the mould.

•Once the mould cavity is filled, the pressure in the

crucible is removed and remaining molten metal flows
back to the crucible.

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 LOW PRESSURE DIE CASTING(2/3)
•After the casting is solidified, the die gets opened and
the product of desired shape is taken out.

Fig.4 Low Pressure Die Casting https://sso.altair.com/

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LOW PRESSURE DIE CASTING(3/3)

ADVANTAGES:
• Good surface finish obtained
•Inexpensive for large scale manufacturing.

DISADVANTAGES:
•Complex and expensive equipment
• Slower casting cycles.

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 SQUEEZE CASTING(1/5)

•Squeeze Casting process is also called as Liquid Forging.

•The product formation in this process involves punching

the molten metal into a high pressure with a tight seal.

•Then the metal rapidly losses its heat and solidifies into
the desired shape.

•After getting desired shape, punch is pulled back.

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 SQUEEZE CASTING(2/5)

Fig.5 Squeeze casting https://www.sciencedirect.com/topics/engi

neering/squeeze-casting

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 SQUEEZE CASTING(3/5)
TYPES OF SQUEEZE CASTING:

Direct Squeeze casting:

The pressure is applied directly to the melt.

Indirect squeeze casting:

•In this, first the metal is injected into the die cavity by a
Piston.
• Then the pressure is transmitted from the hydraulic
Source.

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 SQUEEZE CASTING(4/5)

Fig.6 Indirect Squeeze casting

https://www.sciencedirect.com/science/article/abs/pi
i/S0924013699002915

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 SQUEEZE CASTING(5/5)
ADVANTAGES:
• Offers a broader range of shapes
• Good surface finish
•Fine grain size, so good mechanical properties.

DISADVANTAGES:
• Difficult to achieve homogeneity
•Costs are very high due to complex tooling.

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 REFERENCES
Manufacturing Technology, Vol-1, 5th Edition/P N RAO/6.4, 6.5, 6.6, 6.9
https://www.sciencedirect.com/topics/engineering/casting-process
https://tfmindustrial.com/vacuum-casting-manufacturing/
https://learnmech.com/squeeze-casting-process-advantages-disadvantages/
http://4mechtech.blogspot.com/
https://www.ke-mag.com/issue-42/article/low-pressure-vs-high-pressure-die-c
asting.html

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