Exp1.

Casting
 Casting
• Casting is the process of forming objects by pouring liquid or viscous
material into a prepared mold or form which contains a hollow cavity
of the desired shape, and then allowed to solidify. The solidified part
is also known as a casting, which is ejected or broken out of the mold
to complete the process
• Various Casting processes have been developed; each has its own
characteristics and applications to meet specific engineering and
service requirements, these processes are:
• Sand casting
• Die Casting
 Casting
• Sand casting is the method we’ll use in the lab
• Most sand casting operations use silica sand (SiO2):
• It is inexpensive and suitable as mold material because of its
resistance to high temperatures.
• Good permeability of molds and cores allows gases and steam
evolved to escape easily
• The mold should have good collapsibility to avoid defects in the
casting such as (hot tearing and cracking).
 Casting
• Flask: a flask is a wood or metal frame in which a mold is made
• Pouring basin: Into which the molten metal is poured
• Sprue: through which the molten metal flows downward
• Runner system: channels to carry the molten metal from the sprue to the
mold cavity
• Gates are inlets into the mold cavity.
• Risers:
supply additional metal to the casting as it shrinks during
solidification
• Cores: inserts made from sand. They are placed in the mold to form
hollow regions or otherwise define the interior surface of the casting

• Vents: carry off gases produced when the molten metal

comes in contact with the sand in the molds and core. Also exhaust air from the mold cavity comes out through vents as the molten metal
flows into the mold
 Casting
• Patterns for casting:
• The first step in making a casting is to prepare a model, known as a
pattern.
• To compensate for any dimensional and structural changes which will
happen during the casting or patterning process, allowances are usually
made in the pattern such as:
• Shrinkage allowance
• Draft allowance
• Distortion allowance
• Finishing or Machining allowance
 Casting
• Defects

• Liquid metal penetrates into the molding

sand. This causes a rough surface finish

• Occurs when standard feed metal isn’t

available to compensate for shrinkage as
the thick metal solidifies

• Dissolved gases (poor venting)