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Types of Casting

Casting is the process of pouring molten metal into a mold containing a cavity. Sand casting is by far the most common and possibly the most versatile of the casting processes. Green sand consists of silica sand mixed with 3 % coal dust, 6% clay and 3% alumina.

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121 views

Types of Casting

Casting is the process of pouring molten metal into a mold containing a cavity. Sand casting is by far the most common and possibly the most versatile of the casting processes. Green sand consists of silica sand mixed with 3 % coal dust, 6% clay and 3% alumina.

Uploaded by

ghazalanow
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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CHEP Manufacturing Engineering Senior

MANF 590 Material Fabrication Report # (4) Casting Methods By: Mohamed Magdy Abd-El Rahman To: Dr. Adel B. El-Shabasy Date: 2/10/2012

a. Definition:
Casting is the process of pouring molten metal into a mould containing a cavity, which represents the required product shape.

b. Sand Casting:
Sand casting is by far the most common and possibly the most versatile of the casting processes, accounting for over 90% of all metal castings. Granular refractory material (such as silica, zircon, olivine, or chromite sand) is mixed with small amounts of other materials, such as clay and water, and is then packed around a pattern that has the shape of the desired casting.

a) Process to produce a casting:


We begin by constructing a pattern, an approximate duplicate of the final casting. Molding material will then be packed around the pattern and the pattern is removed to create all or part of the mold cavity. The rigid metal or wood frame that holds the molding aggregate is called a flask. In a horizontally parted two-part mold, the top half of the pattern, flask, mold, or core is called the cope. The bottom half of any of these features is called the drag. A core is a sand (or metal) shape that is inserted into a mold to produce the internal features of a casting, such as holes or passages for water cooling. Cores are produced in wood, metal, or plastic tooling, known as core boxes. A core print is a feature that is added to a pattern, core, or mold and is used to locate and support a core within the mold. The mold material and the cores then combine to produce a completed mold cavity, a shaped hole into which the molten metal is poured and solidified to produce the desired casting. A riser is an additional void in the mold that also fills with molten metal. Its purpose is to provide a reservoir of additional liquid that can flow into the mold cavity to compensate for any shrinkage that occurs during solidification. By designing so the riser contains the last material to solidify, shrinkage voids should be located in the riser, not the final casting.

b) Types of Sand in Sand Casting:


Green Sand: It consists of silica sand mixed with 3 % coal dust, 6% clay and 3.5 % water to act
as strength enhancing binder.

CO2 Setting Sand: this is sodium silicate based sand that chemically hardens when CO2 gas
is passed through it giving a much harder moulding surface. Its used for costly alloy steel casting work.

Core Sand: the different about core sand is that it doesnt contain clay but we use a resin as a
binder instead. We often use reinforcing wires to to give structural strength to withstand handling during mould assembly.

c. Permanent Mould Casting:


In the permanent-mold casting process, also called gravity die casting, a reusable mold is machined from gray cast iron, alloy cast iron, steel, bronze, graphite, or other material. The molds are usually made in segments, which are often hinged to permit rapid and accurate opening and closing. After preheating, a refractory or mold coating is applied to the preheated mold, and the mold is clamped shut. Molten metal is then poured into the pouring basin, and it flows through the feeding system into the mold cavity by simple gravity flow. After solidification, the mold is opened and the product is removed.

a) Low Pressure Die Casting:


In low-pressure and vacuum permanent-mold casting, the mould is turned upside down and positioned above a sealed, airtight chamber that contains a crucible of molten metal. A small pressure difference then causes the molten metal to flow upward into the die cavity. In the lowpressure permanent-mould (LPPM) process, a low-pressure gas (3 to 15 psi) is introduced into a sealed chamber, driving molten metal up through a refractory fill tube and into the gating system or cavity of a metal mould. This metal is exceptionally clean, since it flows from the center of the melt and is fed directly into the mould, never passing through the atmosphere.

b) Hot Chamber Die Casting:


Hot-chamber die-casting machines offer fast cycling times (set by the ability of the water-cooled dies to cool and solidify the metal) and the added advantage that the molten metal is injected from the same chamber in which it is melted (i.e., there is no handling or transfer of molten metal). Unfortunately, the hot-chamber design cannot be used for the higher-melting-point metals, and it is unattractive for aluminum since the molten aluminum tends to pick up some iron during the extended time of contact with the casting equipment. Hot-chamber machines, therefore, primary use with zinc-, tin-, and lead-based alloys.

c) Cold Chamber Die Casting:


Cold-chamber machines are usually employed for the die casting of materials that are not suitable for the hot-chamber design. These include alloys of aluminum, magnesium, and copper as well as high-aluminum zinc. Metal that has been melted in a separate furnace is transported to the diecasting machine, where a measured quantity is fed into an unheated shot chamber (or injection cylinder) and subsequently driven into the die by a hydraulic or mechanical plunger. The pressure is then maintained or increased until solidification is complete. Since molten metal must be

transferred to the chamber for each shot, the cold-chamber process has a longer operating cycle compared to hot-chamber machines.

d. Centrifugal Casting:
The inertial forces of rotation or spinning are used to distribute the molten metal into the mold cavity or cavities in the centrifugal casting processes. In centrifugal casting, a dry-sand, graphite, or metal mold is rotated about either a horizontal or vertical axis at speeds of 300 to 3000 rpm. As the molten metal is introduced, it is flung to the surface of the mold, where it solidifies into some form of hollow product. The exterior profile is usually round (as with gun barrels, pipes, and tubes), but hexagons and other symmetrical shapes are also possible.

e. Continuous Casting:
Continuous casting is usually employed in the solidification of basic shapes that become the feedstock for deformation processes such as rolling and forging. By producing a special mould, continuous casting can also be used to produce long lengths of complex cross-section product. Since each product is simply a cutoff section of the continuous strand, a single mold is all that is required to produce a large number of pieces. Quality is high as well, since the metal can be

protected from contamination during melting and pouring, and only a minimum of handling is required.

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