Manufacturing technology

MEC205
Centrifugal casting
casting defects
Centrifugal casting
•It is a process in which mold is rotated about its central axis as the
metal is poured into it.
•Due to centrifugal force , a continuous pressure will be acting on the
metal as it solidifies.
•According to shape of mold, the centrifugal casting method can be
classified as
Three types of centrifugal casting
1. True centrifugal casting
2. Semi centrifugal casting
3. centrifuging
Centrifugal casting
According to shape of mold, the centrifugal casting method can be
classified as
Three types of centrifugal casting
1. True centrifugal casting
2. Semi centrifugal casting
3. centrifuging
Centrifugal casting
1. True centrifugal casting
•This is normally used for making hollow pipes, tubes etc. which are
axi-symmetric with a concentric hole.
•No core is needed for making concentric hole
•Axis of rotation can be horizontal or vertical or at any angle in
between.
•Outside shape of casting can be round, octagonal, hexagonal, etc ,
but inside shape is (theoretically) perfectly round, due to radially
symmetric forces.
•The castings have a dense metal structure with all impurities forced
back to the centre where frequently they can be machined out.
Centrifugal casting
1. True centrifugal casting
The metal is forced against the walls
on the mold with a centrifugal force
of approximately 70 g, which is a
force 70 times that of the force of
gravity
Centrifugal casting
1. True centrifugal casting
Pipe Casting Machine Iron Flowing into the Mold at ~2340°F

•Plant produces about 4 miles of

pipe/day

•Pipe are approximately 85-90%

recycled materials.
Centrifugal casting
2. Semi centrifugal casting
• items  like wheels  and  pulleys  are  occasionally  cast  in   a  
Semi centrifugal.
•This   type  of  mold  need  not  be  rotated  as  fast  as  in  the  case
 of   a  true  centrifugal  casting
•  As  the   wheel  rotates  around  its  hub  core,  the  mold  cavity  is
filled  from  rim‐to‐hub
•  This  action  promotes   the  direction  of  solidification  from  rim‐to‐
hub  and   provides  the  required  feeding  by  using  only  one  central  
reservoir
Centrifugal casting
2. Semi centrifugal casting
• In semi centrifugal casting mold is completely filled by material
• Casting manufactured by this process will posses rotational
symmetric.
 3. Centrifuged Casting

•Mold impressions are grouped around a

central down-gate
•Centrifugal force is used for filling
Defects in centrifugal casting
1. Hot tear- longitudinal tears occurs due to contraction of casting
combines with expansion of the mold.
2. Segregation- due to centrifugal action, less dense constituents
moves at center.
3. Bending- vibration may cause bending

Segregation
Hot tear- Bending
 Casting defects
•There are numerous opportunities for things to go wrong in a casting
operation, resulting in quality defects in the product.
•Mostly casting defects are concerned with process parameters .
•Casting defect analysis is the process of finding root causes of
occurrence of defects in the rejection of casting
The defects can be classified as follows:
1. General defects common to all casting processes
2. Defects related to sand casting process
 Casting defects
General Defects: Misrun
•A casting that has solidified before completely filling mold cavity
•The edges adjacent to the missing section are
slightly rounded
 Casting defects

General Defects: Misrun

Possible causes:

1. Insufficient quantity of liquid metal in the ladle

2.Premature interruption of pouring due to workman’s error.

Remedies

1. Have sufficient metal in the ladle to fill the mold,Check the

gating system
2. Check the gating system
 Casting defects

General Defects: Cold Shut

Two portions of metal flow together but there is a lack of fusion
due to premature freezing
 Casting defects

General Defects: Cold Shot

Metal splatters during pouring and solid globules form and
become entrapped in casting
 Casting defects

General Defects: Shrinkage Cavity

•Depression in surface or internal void caused by solidification
shrinkage that restricts amount of molten metal available in last
region to freeze.
•Two type- Open shrinkage and closed shrinkage
 Casting defects
Sand Casting Defects: Sand Blow

Balloon‑shaped gas cavity caused by release of mold gases

during pouring
 Casting defects
Sand Casting Defects: Pin holes
Formation of many small gas cavities at or slightly below
surface of casting
 Casting defects
Sand Casting Defects: Penetration
When fluidity of liquid metal is high, it may penetrate into sand
mold or core, causing casting surface to consist of a mixture of
sand grains and metal
 Casting defects
Sand Casting Defects: Mold shift
A step in cast product at parting line caused by sidewise
relative displacement of cope and drag