FUNDAMENTALS OF METAL

CASTING

1. Overview of Casting Technology

2. Heating and Pouring
3. Solidification and Cooling

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification Processes

Starting work material is either a liquid or is in a highly

plastic condition, and a part is created through
solidification of the material
 Solidification processes can be classified according to
engineering material processed:
 Metals
 Ceramics, specifically glasses
 Polymers and polymer matrix composites (PMCs)

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Classification of solidification processes

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Casting of Metals

Process in which molten metal flows by gravity or other

force into a mold where it solidifies in the shape of
the mold cavity
 The term casting also applies to the part made in the
process
 Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Capabilities and Advantages of
Casting
 Can create complex part geometries
 Can create both external and internal shapes
 Some casting processes are net shape; others are
near net shape
 Can produce very large parts
 Some casting methods are suited to mass production

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Disadvantages of Casting

 Different disadvantages for different casting

processes:
 Limitations on mechanical properties
 Poor dimensional accuracy and surface finish for
some processes; e.g., sand casting
 Safety hazards to workers due to hot molten
metals
 Environmental problems

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Parts Made by Casting

 Big parts
 Engine blocks and heads for automotive
vehicles, wood burning stoves, machine frames,
railway wheels, pipes, church bells, big statues,
pump housings
 Small parts
 Dental crowns, jewelry, small statues, frying
pans

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Overview of Casting Technology

 Casting is usually performed in a foundry

Foundry = factory equipped for making molds, melting
and handling molten metal, performing the casting
process, and cleaning the finished casting
 Workers who perform casting are called foundrymen

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 The Mold in Casting

 Contains cavity whose geometry determines part

shape
 Actual size and shape of cavity must be slightly
enlarged to allow for shrinkage of metal during
solidification and cooling
 Molds are made of a variety of materials,
including sand, plaster, ceramic, and metal

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Open Molds and Closed Molds

 Two forms of mold: (a) open mold and (b) closed mold
for more complex mold geometry with gating system
leading into the cavity

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Two Categories of
Casting Processes

1. Expendable mold processes – use an expendable

mold which must be destroyed to remove casting
 Mold materials: sand, plaster, and similar
materials, plus binders
2. Permanent mold processes – use a permanent mold
which can be used to produce many castings
 Made of metal (or, less commonly, a ceramic
refractory material

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Advantages and Disadvantages

 More intricate geometries are possible with

expendable mold processes
 Part shapes in permanent mold processes are limited
by the need to open the mold
 Permanent mold processes are more economic in
high production operations

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Sand Casting Mold

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Terminology for
Sand Casting Mold
 Mold consists of two halves:
 Cope = upper half of mold
 Drag = bottom half
 Mold halves are contained in a box, called a flask
 The two halves separate at the parting line

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Forming the Mold Cavity
in Sand Casting
 Mold cavity is formed by packing sand around a
pattern, which has the shape of the part
 When the pattern is removed, the remaining cavity of
the packed sand has desired shape of cast part
 The pattern is usually oversized to allow for shrinkage
of metal during solidification and cooling
 Sand for the mold is moist and contains a binder to
maintain its shape

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Use of a Core in the Mold Cavity

 The mold cavity provides the external surfaces of the

cast part
 In addition, a casting may have internal surfaces,
determined by a core, placed inside the mold cavity
to define the interior geometry of part
 In sand casting, cores are generally made of sand

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Gating System

Channel through which molten metal flows into cavity

from outside of mold
 Consists of a downsprue, through which metal enters
a runner leading to the main cavity
 At the top of downsprue, a pouring cup is often used
to minimize splash and turbulence as the metal flows
into downsprue

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Riser

Reservoir in the mold which is a source of liquid metal

to compensate for shrinkage of the part during
solidification
 The riser must be designed to freeze after the main
casting in order to satisfy its function

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Heating the Metal

 Heating furnaces are used to heat the metal to

molten temperature sufficient for casting
 The heat required is the sum of:
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal to desired
temperature for pouring

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Pouring the Molten Metal

 For this step to be successful, metal must flow into all

regions of the mold, most importantly the main cavity,
before solidifying
 Factors that determine success
 Pouring temperature
 Pouring rate
 Turbulence

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification of Metals

Transformation of molten metal back into solid state

 Solidification differs depending on whether the metal
is
 A pure element or
 An alloy

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Cooling Curve for a Pure Metal

 A pure metal
solidifies at a
constant
temperature equal
to its freezing
point (same as
melting point)

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification of Pure Metals

 Due to chilling action of mold wall, a thin skin of solid

metal is formed at the interface immediately after
pouring
 Skin thickness increases to form a shell around the
molten metal as solidification progresses
 Rate of freezing depends on heat transfer into mold,
as well as thermal properties of the metal

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification of Pure Metals

 Characteristic grain
structure in a casting of
a pure metal, showing
randomly oriented
grains of small size near
the mold wall, and large
columnar grains
oriented toward the
center of the casting

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification of Alloys

 Most alloys freeze over a temperature range

 Phase diagram for a copper‑nickel alloy system and
cooling curve for a 50%Ni‑50%Cu composition

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification of Alloys

 Characteristic grain
structure in an alloy
casting, showing
segregation of alloying
components in center
of casting

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification Time

 Total solidification time TTS = time required for casting

to solidify after pouring
 TTS depends on size and shape of casting by
relationship known as Chvorinov's Rule
n
 
V
TTS  Cm  
 A
where TTS = total solidification time; V = volume of the
casting; A = surface area of casting; n = exponent
with typical value = 2; and Cm is mold constant.
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Mold Constant in Chvorinov's
Rule

 Mold constant Cm depends on:

 Mold material
 Thermal properties of casting metal
 Pouring temperature relative to melting point
 Value of Cm for a given casting operation can be
based on experimental data from previous operations
carried out using same mold material, metal, and
pouring temperature, even though the shape of the
part may be quite different
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 What Chvorinov's Rule Tells Us

 Casting with a higher volume‑to‑surface area ratio cools

and solidifies more slowly than one with a lower ratio
 To feed molten metal to the main cavity, TTS for
riser must be greater than TTS for main casting
 Since mold constants of riser and casting will be equal,
design the riser to have a larger volume‑to‑area ratio so
that the main casting solidifies first
 This minimizes the effects of shrinkage

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Shrinkage during Solidification
and Cooling
 (0) starting level of molten metal immediately after
pouring; (1) reduction in level caused by liquid
contraction during cooling

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Shrinkage during Solidification
and Cooling
 (2) reduction in height and formation of shrinkage cavity
caused by solidification; (3) further reduction in volume
due to thermal contraction during cooling of solid metal

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Solidification Shrinkage

 Occurs in nearly all metals because the solid phase

has a higher density than the liquid phase
 Thus, solidification causes a reduction in volume per
unit weight of metal
 Exception: cast iron with high C content
 Graphitization during final stages of freezing
causes expansion that counteracts volumetric
decrease associated with phase change

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Shrinkage Allowance

 Patternmakers correct for solidification shrinkage and

thermal contraction by making the mold cavity
oversized
 Amount by which mold is made larger relative to final
casting size is called pattern shrinkage allowance
 Casting dimensions are expressed linearly, so
allowances are applied accordingly

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Directional Solidification

 To minimize effects of shrinkage, it is desirable for

regions of the casting most distant from the liquid
metal supply to freeze first and for solidification to
progress from these regions toward the riser(s)
 Thus, molten metal is continually available from
risers to prevent shrinkage voids
 The term directional solidification describes this
aspect of freezing and methods by which it is
controlled

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Achieving Directional
Solidification
 Directional solidification is achieved using
Chvorinov's Rule to design the casting, its orientation
in the mold, and the riser system that feeds it
 Locate sections of the casting with lower V/A
ratios away from riser, so freezing occurs first in
these regions, and the liquid metal supply for the
rest of the casting remains open
 Chills ‑ internal or external heat sinks that cause
rapid freezing in certain regions of the casting

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 External Chills

 (a) External chill to encourage rapid freezing of the

molten metal in a thin section of the casting; and (b) the
likely result if the external chill were not used

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
 Riser Design

 Riser is waste metal that is separated from the

casting and remelted to make more castings
 To minimize waste in the unit operation, it is desirable
for the volume of metal in the riser to be a minimum
 Since the shape of the riser is normally designed to
maximize the V/A ratio, this allows riser volume to be
reduced to the minimum possible value

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e