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Module 3

The document discusses various metal casting processes including vacuum casting, gravity die casting, centrifugal casting, thixocasting, and rheocasting, highlighting their applications, advantages, and disadvantages. Vacuum casting is suitable for thin-walled components, while gravity die casting uses reusable molds for various parts. Centrifugal casting produces cylindrical shapes, and thixocasting and rheocasting focus on semi-solid materials, with rheocasting offering cost advantages over thixocasting.

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sharvesh.b2023
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1 views

Module 3

The document discusses various metal casting processes including vacuum casting, gravity die casting, centrifugal casting, thixocasting, and rheocasting, highlighting their applications, advantages, and disadvantages. Vacuum casting is suitable for thin-walled components, while gravity die casting uses reusable molds for various parts. Centrifugal casting produces cylindrical shapes, and thixocasting and rheocasting focus on semi-solid materials, with rheocasting offering cost advantages over thixocasting.

Uploaded by

sharvesh.b2023
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Suitable particularly for thin-walled complex shapes, with uniform properties.

Typical parts made are superalloy gas-


turbine components with walls as thin as 0.5 mm.
 Vacuum casting, as the name suggests, is the type of casting where production occurs
under vacuum pressure of 100 bar or less to exhaust gas from the mold cavity. In this
process, molten metal is poured into the mold cavity inside a vacuum chamber in order
to eliminate bubbles and air pockets.
 The vacuum evacuation of the die cavity reduces the entrapment of gases within the
cavity during the metal injection process. Finally, the metal is cured in a heating chamber
and removed from the mold.
 The vacuum die casting process is popular in various industries including automobiles,
aerospace, electronics, marine, telecommunication, etc. As a result, some components
fabricated by this manufacturing process include structural chassis components and
automotive body parts.
or Die Casting
 Gravity die casting, also typically known as permanent mold casting, uses reusable molds
made of metal, like steel, graphite etc. to fabricate metal and metal alloys. This type of
metal casting can manufacture various parts like gears, gear housing, pipe fittings, wheels,
engine pistons, etc.

 In this process, the direct pouring of molten metal into the mold cavity takes place under
the effect of gravity. For better coverage, the die can be tilted to control the filling. The
molten metal is then allowed to cool and solidifies within the mold to form products. As a
result, this process makes casting of materials like lead, zinc, aluminum, and magnesium
alloys, certain bronzes, and cast iron more common.

 This casting process works on the bottom-up approach to fill the mold, in contrast, to
other pressure casting processes. Although, the process has a higher casting rate than
sand casting. But, it is relatively higher in cost due to expensive metal molds. Check its
advantages and disadvantages below.
vertical centrifugal casting process
 Centrifugal casting, also known as roto casting, is a process for industrially manufacturing
cylindrical parts with centrifugal forces. This type of metal casting uses a preheated
spinning die in which the molten metal is poured. The centrifugal forces help to distribute
the molten metal within the die at high pressure.

 Three variations of centrifugal casting exist; true centrifugal casting process, semi
centrifugal casting process, and vertical centrifugal casting process. Semi centrifugal
casting, unlike true centrifugal casting, has the mold completely filled using a sprue.
However, in true centrifugal casting, molten metal sticks to the sides due to continuous
rotation. On the contrary, vertical centrifugal casting, as the name suggests, uses
directional molding following the same process as true centrifugal casting.

 Typically, centrifugal casting produces rotational shapes like cylinders. In particular, parts
like bush bearings, clutch plates, piston rings, and cylinder liners, etc. Also, the pouring of
metal in the center of the mold helps in reducing defects such as blow holes, shrinkage,
and gas pockets. However, it is not suitable for all kinds of metal alloys.
Thixocasting utilizes a pre-cast billet with a non-dendritic microstructure that is normally produced
by vigorously stirring the melt as the bar is being cast.

Induction heating is normally used to re-heat the billets to the semi-solid temperature range, and die
casting machines are used to inject the semi-solid material into hardened steel dies.

Thixocasting is being performed commercially in North America, Europe and Asia.

Thixocasting has the ability to produce extremely high quality components due to the product
consistency that results from using pre-cast billet that is manufactured under the same ideal continuous
processing conditions that are employed to make forging or rolling stock.

The main disadvantage is that it is expensive due to the special billets that must be used, although
facilities with in house magnetohydrodynamic continuous casting capabilities can recycle 100% of in-
house returns.

Other disadvantages include a limited number of alloys, and for facilities without in-house
magnetohydrodynamic casting capability scrap cannot be directly reused.
Rheocasting

Unlike thixocasting, which re-heats a billet, rheocasting develops the semi-solid


slurry from the molten metal produced in a typical die casting furnace.

This is a big advantage over thixocasting because it results in less expensive


feedstock, in the form of typical die casting alloys, and allows for direct recycling.

However, rheocasting also poses process control issues such that after an initial
surge of activity, very little material is processed via rheocasting.

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