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AssocProfZainalAbidinAhmad
DepartmentofManufacturing&Ind.Eng.
UniversitiTeknologiMalaysia
METALCASTINGPROCESSES
CastingQuality CastingQuality
MetalsforCasting
ProductDesignConsiderations
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CastingQuality
Therearenumerousopportunitiesforthingstogowrong pp g g g
inacastingoperation,resultinginqualitydefectsinthe
product
Thedefectscanbeclassifiedasfollows:
Defectscommontoallcastingprocesses
Defectsrelatedtosandcastingprocess
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Misrun
Acastingthathassolidifiedbeforecompletelyfilling
moldcavity
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Figure 11.22 - Some common defects in castings: (a) misrun
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ColdShut
Twoportionsofmetalflowtogetherbutthereisalackoffusiondue
toprematurefreezing
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Figure 11.22 - Some common defects in castings: (b) cold shut
ColdShot
Metalsplattersduringpouringandsolidglobulesform
andbecomeentrappedincasting
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Figure 11.22 - Some common defects in castings: (c) cold shot
ShrinkageCavity
Depressioninsurfaceorinternalvoidcausedbysolidification
shrinkagethatrestrictsamountofmoltenmetalavailableinlast
regiontofreeze
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Figure 11.22 - Some common defects in castings: (d) shrinkage cavity
SandBlow
Balloonshapedgascavitycausedbyreleaseofmoldgases
duringpouring
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Figure 11.23 - Common defects in sand castings: (a) sand blow
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PinHoles
Formationofmanysmallgascavitiesatorslightlybelow
surfaceofcasting
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Figure 11.23 - Common defects in sand castings: (b) pin holes
Penetration
Whenfluidityofliquidmetalishigh,itmaypenetrate
intosandmoldorsandcore,causingcastingsurfaceto
i t f i t f d i d t l consistofamixtureofsandgrainsandmetal
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Figure 11.23 - Common defects in sand castings: (e) penetration
MoldShift
Astepincastproductatpartinglinecausedbysidewise
relativedisplacementofcopeanddrag
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Figure 11.23 - Common defects in sand castings: (f) mold shift
MetalsforCasting
Mostcommercialcastingsaremadeofalloys Mostcommercialcastingsaremadeofalloys
ratherthanpuremetals
Alloysaregenerallyeasiertocast,andpropertiesof
productarebetter
Castingalloyscanbeclassifiedas:
Ferrous
Nonferrous
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FerrousCastingAlloys:CastIron
Mostimportantofallcastingalloys
Tonnageofcastironcastingsisseveraltimesthatofallother
metalscombined
Severaltypes:(1)graycastiron,(2)nodulariron,(3)white
castiron,(4)malleableiron,and(5)alloycastirons
Typicalpouringtemperatures 1400C(2500F),depending Typicalpouringtemperatures 1400 C(2500 F),depending
oncomposition
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FerrousCastingAlloys:Steel
Themechanicalpropertiesofsteelmakeitanattractive p p
engineeringmaterial
Thecapabilitytocreatecomplexgeometriesmakescasting
anattractiveshapingprocess
Difficultiesfacedbythefoundryworkingwithsteel:
Pouringtemperatureofsteelishigherthanformostothercasting
metals 1650C(3000F) 5 (3 )
Atthesetemperatures,steelreadilyoxidizes,somoltenmetalmust
beisolatedfromair
Moltensteelhasrelativelypoorfluidity
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NonferrousCastingAlloys:Aluminum
G ll id d b bl Generallyconsideredtobeverycastable
Pouringtemperatureslow meltingtemperatureof
aluminumT
m
=660C(1220F)
Properties:
Lightweight
Rangeofstrengthpropertiesbyheattreatment
Easeofmachining
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NonferrousCastingAlloys:CopperAlloys
Includesbronze,brass,andaluminumbronze
Properties:
Corrosionresistance
Attractiveappearance
Goodbearingqualities
Limitation:highcostofcopper g pp
Applications:pipefittings,marinepropellerblades,pump
components,ornamentaljewelry
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NonferrousCastingAlloys:ZincAlloys
Hi hl bl l di di i Highlycastable,commonlyusedindiecasting
Lowmeltingpoint meltingpointofzincT
m
=419C
(786F)
Goodfluidityforeaseofcasting
Properties:
Lowcreepstrength,socastingscannotbesubjectedtoprolonged p g g j p g
highstresses
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TypicalApplicationsforCastingandCasting
Characteristics
TABLE 12.2
Type of alloy Application Castability* Weldability* Machinability*
Aluminum Pistons, clutchhousings, intake
manifolds
E F GE
Copper Pumps, valves, gear blanks,
i ll
FG F FG
marinepropellers
Ductileiron Crankshafts, heavy-duty gears G D G
Gray iron Engineblocks, gears, brakedisks
anddrums, machinebases
E D G
Magnesium Crankcase, transmissionhousings GE G E
Malleableiron Farmandconstructionmachinery,
heavy-duty bearings, railroad
rollingstock
G D G
Nickel Gasturbineblades, pumpand
valvecomponentsfor chemical
plants
F F F
Steel (carbonand
lowalloy)
Dieblocks, heavy-duty gear
blanks, aircraft undercarriage
F E F
low alloy) blanks, aircraft undercarriage
members, rail-roadwheels
Steel (highalloy) Gasturbinehousings, pumpand
valvecomponents, rock crusher
jaws
F E F
Whiteiron Mill liners, shot blastingnozzles,
railroadbrakeshoes, crushersand
pulverizers
G VP VP
Zinc Door handles, radiator grills, E D E
*E, excellent; G, good; F, fair; VP, very poor; D, difficult.
ProductDesignConsiderations:Geometric
Simplicity
Althoughcastingcanbeusedtoproducecomplexpart g g p p p
geometries,simplifyingthepartdesignwillimprove
castability
Avoidingunnecessarycomplexities:
Simplifiesmoldmaking
Reducestheneedforcores
Improvesthestrengthofthecasting p g g
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Figure 12.6
Examples of casting
design
modifications.
Source: Steel
Casting Handbook,
5th ed. Steel
Founders' Society of
America 1980 America, 1980.
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ProductDesignConsiderations:
Corners
Sharpcornersandanglesshouldbeavoided,sincetheyare p g , y
sourcesofstressconcentrationsandmaycausehottearing
andcracks
Generousfilletsshouldbedesignedoninsidecornersand
sharpedgesshouldbeblended
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CastingDesignModifications
Figure 12.1 Suggested
design modifications to
avoid defects in castings.
Note that sharp corners
areavoidedtoreduce are avoided to reduce
stress concentrations.
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CastingCrossSections
Figure 12.2 Examples of designs showing the importance of
maintaining uniform cross- sections in castings to avoid hot
spots and shrinkage cavities.
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Figure 12.3 Examples
AvoidingShrinkageCavities
of design modifications
to avoid shrinkage
cavities in castings.
Source: Steel Castings
Handbook, 5th ed.
Steel Founders' Society
f A i 1980 of America, 1980.
Used with permission.
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Figure 12.4 The
f t l
Chills
use of metal
padding (chills)
to increase the
rate of cooling in
thick regions in a
casting to avoid
shrinkage shrinkage
cavities.
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ProductDesignConsiderations:
DraftGuidelines
Inexpendablemoldcasting,purposeofdraftistofacilitate
removalofpatternfrommold(1 forsandcasting)
Inpermanentmoldcasting,purposeistoaidinremovalofthe
partfromthemold(2 to3 forpermanentmoldprocesses)
Similartapersshouldbeallowedifsolidcoresareused
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ProductDesignConsiderations:
DimensionalTolerancesandSurfaceFinish
Significantdifferencesindimensionalaccuraciesandfinishes
canbeachievedincastings,dependingonprocess:
Poordimensionalaccuraciesandfinishforsandcasting
Gooddimensionalaccuraciesandfinishfordiecastingand
investmentcasting
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ProductDesignConsiderations:Machining
Allowances
Almostallsandcastingsmustbemachinedtoachievethe g
requireddimensionsandpartfeatures
Additionalmaterial,calledthemachiningallowance,must
beleftonthecastinginthosesurfaceswheremachiningis
necessary
Typicalmachiningallowancesforsandcastingsarearound
1 5to3mm(1/16to1/4in) 1.5to3mm(1/16to1/4in)
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NormalShrinkageAllowanceforSomeMetalsCastin
SandMolds
TABLE 12.1
Metal Percent Metal Percent
Gray cast iron
White cast iron
Malleable cast iron
Aluminum alloys
Magnesium alloys
Yellow brass
Ph h b
0.831.3
2.1
0.781.0
1.3
1.3
1.31.6
10 16 Phosphor bronze
Aluminum bronze
High-manganese steel
1.01.6
2.1
2.6
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Figure 12.5 Redesign
f ti b ki
PartingLines
of a casting by making
the parting line
straight to avoid
defects. Source: Steel
Casting Handbook,
5th ed. Steel
Founders' Societyof Founders Society of
America, 1980.
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DesirableandUndesirableDieCastingPractices
Figure 12.7
Examplesof Examples of
undesirable and
desirable design
practices for die-cast
parts. Note that
section-thickness
uniformityis uniformity is
maintained
throughout the part.
Source: American Die
Casting Institute.