Metal Casting Processes

A.BALARAM NAIK

Associate Professor of Mechanical Engg

Department of Mechanical Engineering

JNTUH College of Engineering Hyderabad
Kukatpally, Telangana State.
 Manufacturing Processes
Manufacturing involves the conversion of raw materials, usually supplied in simple or
shapeless forms, into finished products with specific shape, structure, and properties that fulfil
given requirements.
This conversion into finished products is accomplished using a great variety of processes that
apply energy to produce controlled changes in the configuration properties of materials.
The energy applied during processing may be mechanical, thermal, electrical, or chemical in
nature.
The results are meant to satisfy functional requirements that were defined during the product
design stage.. In the past, design, materials engineering, and manufacturing were often
treated as independent engineering specialties.
However, modem manufacturing must be cost-effective and timely. This requires that
everyone involved in the entire product life cycle work together concurrently to provide a
functional product that can be produced efficiently, can be operated reliably, and is easy to
maintain and recycle (Taguchi, 1993).
 Unit Manufacturing Process
Manufacturing a product or component usually requires the integration of a
number of processes.
For example, the initial process may involve casting a metal into a mould to
produce a desired shape. Next, the casting may be machined with cutting tools
to generate surfaces of specified form. Finally, a surface treatment may be
employed to improve the durability of the part.
Each of these three individual operations—casting, machining, and surface
treatment—is a unit manufacturing process.
They are the individual steps required to produce finished goods by
transforming raw material and adding value to the workpiece as it becomes a
finished product.
Unit process information and materials flow.
 Unit manufacturing process model
A schematic model of a unit
process is depicted in this figure.
Energy is delivered to the
workpiece material by means of
the process equipment and its
tooling and is transferred to the
workpiece through an interface
region between the tooling and the
workpiece.
Often the interface contains a
medium such as a coolant or
lubricant.
The specific changes in the
workpiece configuration and
structure usually occur in a
localized area of the workpiece,
designated as the workzone.
 TAXONOMY OF UNIT MANUFACTURING PROCESSES
Mass-change processes remove or add material by mechanical,electrical, or chemical means.
Included in this family are the traditional processes of plating, machining, and grinding, as well as
nontraditional removal processes such as electro-discharge and electrochemical machining.
Phase-change processes produce a solid part from material originally in the liquid or vapour
phase. The casting of metals, infiltration of composites, and injection moulding of polymers
represent this family.(Phase changes in the solid state are considered to belong to the
structure-change process family.)
Structure-change processes alter the microstructure of a workpiece,either throughout its bulk or in a
localized area, such as its surface. Heat treatment and surface hardening are commercial processes
representative of this family. Solid-state phase changes are considered part of this family.
Deformation processes alter the shape of a solid workpiece without changing its mass or composition.
Classical metalworking processes of rolling and forging fall into this category, as do the sheet-forming
processes of deep drawing and ironing.
Consolidation processes combine materials such as particles,filaments, or solid sections to form a part
or component. Powder metallurgy, ceramic moulding, and polymer-matrix composite pressing are
examples of consolidation processes. Joining processes, such as welding and brazing, also belong to
this process family.
Unit manufacturing process families, components, and material
Classes
Unit process components and enabling technologies
 Phase-Change Processes
Phase-change processes produce a solid part from liquid material. They include the commercial
processes of metal casting, infiltration of composites, and injection moulding of polymers. These
processes may reside early in the process stream (e.g., ingot casting of wrought metallic
products) or produce a finished component (e.g., a moulded polymeric beverage container).
Control of the part shape and workpiece microstructure to specific levels is a high priority in
these processes and often establishes the economics of the manufacturing process.
Manufacturing processes that change the phase of metals by melting and subsequently re-
solidifying materials into finished or semifinished products are categorized as moulding and
casting processes. Primary metal industries use melting, casting, and solidification processes to
produce semifinished products. Molten metals and alloys are cast by continuous methods or into
individual ingot moulds Subsequently, these primary castings are rolled into semifinished
products such as sheet, plate, rod, and bar, or they are forged into semifinished shapes
(Weidmann, 1990).
In contrast to the primary metals industry, the foundry industry uses a wide variety of molding

and casting processes to produce discrete, shaped products. These products range in size from
steel castings of several hundred tons that are used in power generation plants to small,
precision castings, such as delicate jewellery produced in investment moulds These processes
are typically characterized by their moulding process or by the casting process itself.
METAL CASTING

Dr. Sudhakar C Jamb

Dr. Sudhakar C Jamb
Examples of castings

Dr. Sudhakar C Jamb

Examples of Castings

Dr. Sudhakar C Jamb

Casting Processes
• These are the only processes where liquid
metal in used.
• Casting is the oldest known manufacturing
process.
• It requires preparation of a cavity usually in
a refractory material to resemble closely to
the object to be realized.
• Molten metal is poured into this refractory
mould cavity and is allowed to solidify.
• The object after solidification is removed
from the mould.
 Advantages of
Casting
•Low cost and quick
•Easier to manufacture
•Can produce parts in one piece
•Best suited for composite components
•Can produce intricate shapes and internal openings
•Flow of molten metal
•Solidification and cooling
For successful casting, we need to understand the
following areas:

• Preparations of moulds and patterns

• Melting and pouring of the liquified metal
• Solidification and further cooling to room temperature
• Defects and inspection
How to decide whether the Material is castable or
not:
• The melting temp of the job and the mould materials
• The solubility of and the chemical reaction between the job
and the mould materials
• The solubility of the atmosphere in the material at different
temperatures to be encountered in the casting operation.
• The thermal properties such as conductivity and coefficient
of thermal expansion of both the mold and job materials.
Summary of
Casting
Processes
Solidification Processing of metals and alloys

Rapid Solidification (105 K/s)

Rapidly cool or quench to produce amorphous
or glassy structure (metallic glass)
 
Rapid Solidification

Cooling Rate >104 -107 oK/s

By processes such as: Atomization, melt spinning, roller-
quenching or plasma spray or laser or electron beam surface
treatment

Non-eqm phase, no thermo. Restrictions, exceed solubility
limits, melt solidifies without any chem changes.

Crystalline or amorphous (improved mech. properties)

Microsegregation-free structures

Using powder metallurgy to process the materials.
 Research Priorities in Casting
PRIMARY RESEARCH PRIORITIES:
• Solidification and Casting Technologies
Dimensional Control of Castings
Clean Cast-Metal Technology
• Computational Modelling and Design
Computer Integrated Processing Methods for
Productivity and Quality Improvements
• Processing Technologies and Design for
Energy Efficiency, Material Conservation,
Environmental Protection, or Industrial
Productivity
Aluminium Furnace Optimization
Process Improvements for Lightweight
Components of Aluminium Magnesium and
Thin-Wall Metal Castings
Sand Reclamation
Characterization of Waste Streams
SECONDARY RESEARCH PRIORITIES:
• Solidification and Casting Technologies
Expendable Pattern Casting Technology
• Emerging Areas Needing Research
On-Line Process Controls and Sensors for
Moulding Melting and Core making
Plasma Melting
• Processing Technologies and Design for
Energy Efficiency, Material Conservation,
Environmental Protection, or Industrial
Productivity
Cupola Furnace Optimization
Gating System Removal and Finishing
Operation Technologies