Lecture 2.

1

METAL CASTING
Disposable Mold Casting
Fundamental of metal casting
Introduction

shrinkage
Typical Cast Parts
Figure (a) Typical gray-iron castings used in automobiles, including the transmission valve
body (left) and the hub rotor with disk-brake cylinder (front). Source: Courtesy of Central
Foundry Division of General Motors Corporation. (b) A cast transmission housing. (c)
The Polaroid PDC-2000 digital camera with a AZ191D die-cast high-purity magnesium
case. (d) A two-piece Polaroid camera case made by the hot-chamber die-casting
process.
(a)
(b)
(c)
(d)
Casting of an Aluminum Piston
Figure 10.16 Aluminum piston for an internal combustion engine: (a) as-
cast and (b) after machining.
Solidification of Pure Metals
Figure 10.1 (a) Temperature as a function of time for the solidification of pure metals. Note that the
freezing takes place at a constant temperature. (b) Density as a function of time
Solidification volume shrinkage
Fig. 2.19 Changes in volume as a metal alloy solidifies.
Cast Structures of Solidified Metals
Figure 10.2 Schematic illustration of three cast structures
of metals solidified in a square mold: (a) pure metals; (b)
solid-solution alloys; and (c) structure obtained by using
nucleating agents. Source: After G. W. Form, J. F.
Wallace, J. L. Walker, and A. Cibula
Figure 10.3 Development of a preferred texture at
a cool mold wall. Note that only favorably oriented
grains grow away from the surface of the mold
Alloy Solidification
Figure 10.4 Schematic illustration of alloy solidification and temperature distribution in the
solidifying metal. Note the formation of dendrites in the mushy zone.
Solidification of Iron and Carbon Steels
Figure 10.5 (a) Solidification patterns for gray cast iron in a 180-mm (7-in.) square casting. Note
that after 11 minutes of cooling, dendrites reach each other, but the casting is still mushy
throughout. It takes about two hours for this casting to solidify completely. (b) Solidification of
carbon steels in sand and chill (metal) molds. Note the difference in solidification patterns as the
carbon content increases. Source: After H. F. Bishop and W. S. Pellini
Basic Types of Cast Structures
Figure 10.6 Schematic illustration of three basic types of cast structures: (a) columnar dendritic; (b)
equizxed dendritic; and (c) equiaxed nondendritic. Source: Courtesy of D. Apelian
Cast Structures
Figure 10.7 Schematic illustration of cast structures in (a) plane front, single phase,
and (b) plane front, two phase. Source: Courtesy of D. Apelian
Chill, columnar and equaixial grains
Fig. 2.17 Sketch of solidified grain structure of an alloy: (a) chill crystals; (b) columnar
grains; and (c) region of coarse equiaxed grains in centre.
Fluid Flow and Solidification Time
Sprue design


A
1
A
2
=
h
2
h
1
Mass continuity


Q = A
1
v
1
= A
2
v
2
Bernoullis theorem


h +
p
g
+
v
2
2g
= constant
Reynolds number


Re =
vD
q
Chvorinovs Rule


Solidification time = C
Volume
Surface Area
|
\
|
.
n
Casting Design and Fluidity Test
Figure 10.8 Schematic illustration of a typical riser-gated
casting. Risers serve as reservoirs, supplying molten
metal to the casting as it shrinks during solidification.
Figure 10.9 A test method for fluidity using
a spiral mold. The fluidity index is the length
of the solidified metal in the spiral passage.
The greater the length of the solidified
metal, the greater is its fluidity.
Figure 10.10 Temperature
distribution at the interface of
the mold wall and the liquid
metal during the solidification of
metals in casting
Temperature Distribution during Metal Solidification
Solidified Skin on a Steel Casting
Figure 10.11 Solidified skin on a steel casting. The remaining molten metal is poured out at the times
indicated in the figure. Hollow ornamental and decorative objects are made by a process called slush
casting, which is based on this principle. Source: After H. F. Taylor, J. Wulff, and M. C. Flemings
Solidification Contraction or Expansion
Common Casting Defects
Figure 10.13 Examples of common defects in castings. These defects can be minimized or
eliminated by proper design and preparation of molds and control of pouring procedures.
Source: After J. Datsko.
Types of Internal and External Chills used in Casting
Figure 10.14 Various types of (a) internal and (b) external chills (dark areas at corners) used in
castings to eliminate porosity caused by shrinkage. Chills are placed in regions where there is a
larger volume of metal, as shown in (c).
Solubility of Hydrogen in Aluminum
Figure 10.15 Solubility of
hydrogen in aluminum. Note
the sharp decrease in solubility
as the molten metal begins to
solidify.
Sand casting
SAND CASTING BENEFITS

1. Least Expensive Casting Process
2. Castings can be up to Several Tons
3. Less Expensive than Machining Shapes from Bar
Stock
4. Can Cast Intricate Shapes
5. Can be Used with Most Pourable Metals and Alloys

HOW IT WORKS

The Sand Casting ( Green Sand ) molding process utilizes a cope ( top half ) and drag
( bottom half ) flask set-up. The mold consists of sand, ( usually silica ), clay and water.
When the water is added it develops the bonding characteristics of the clay, which
binds the sand grains together.

When applying pressure to the mold material it can be compacted around a pattern,
which is either made of metal or wood, to produce a mold having sufficient rigidity to
enable metal to be poured into it to produce a casting. The process also uses coring
to create cavities inside the casting. After the casting is poured and has cooled the
core is removed.
The material costs for the process are low and the sand casting process is
exceptionally flexible. A number of metals can be used for castings in sizes from
ounces to many thousand pounds. The mold material is reclaimable, with between 90
and 95% of the sand being recycled, although new sand and additions are required to
make up for the discarded loss. These features, combined with the relative ease of
mold production, have ensured that the green sand molding process has remained as
the principal method by which castings are produced.
The sand casting processes
Mold making
FIGURE 2-9 Steps in making a green
sand mold using a semi-automatic
molding process. (D. L. Zalensas, ed.,
Aluminum Casting Technology, 2nd
ed., 1997, p. 187). Reprinted with
permission from American Foundry
Design for Ease of Removal from Mold
Figure Taper on patterns for ease of removal from the sand mold
THE SAND
The sand used for green sand molding is critical and determines the favorable or
unfavorable outcome of the casting. It controls the tolerances, surface finish and
the repeatability while in production. Remembering that the tolerances on sand
castings are usually wider than the other casting methods.

The sand must exhibit the following characteristics:

1. FLOWABILITY: The ability to pack tightly around the pattern.
2. PLASTIC DEFORMATION: Have the ability to deform slightly without
cracking so that the pattern can be withdrawn.
3. GREEN STRENGTH: Have the ability to support its own weight when stripped
from the pattern, and also withstand pressure of molten metal when the mold
is cast.
4. PERMEABILITY: This allows the gases and steam to escape from the mold
during casting.

All of these requirements are dependent on the amount of active clay present and
on the water content of the mixture.
DEFINITIONS
1. POURING CUP: This is where the metal is poured into the mold.
2. SPRUE: The vertical channel from the top of the mold to the gating and riser system. Also, a generic term
used to cover all gates, runners and risers.
3. RUNNER: The portion of the gate assembly that connects the sprue to the casting in gate or riser.
4. GATE: The end of the runner in a mold where molten metal enters the mold cavity.
5. RISER: A reservoir of molten metal provided to compensate for the contraction of the metal as it
solidifies.
6. MOLD CAVITY: The impression in a mold produced by the removal of the pattern. When filled with
molten metal it forms a casting.
7. COPE: Upper or top most section of a flask, mold or pattern.
8. PARTING LINE: A line on a pattern or casting corresponding to the separation between the parts of a
mold.
9. DRAG: Lower or bottom section of a flask, mold or pattern.

Production Steps in Sand-Casting
Figure Outline of production steps in a typical sand-casting operation.
Design for Ease of Removal from Mold
Figure Taper on patterns for ease of removal from the sand mold
Sequence of Operations for Sand-Casting
Figure Schematic illustration of the sequence of operations for sand casting. (a) A mechanical drawing of the part is
used to generate a design for the pattern. Considerations such as part shrinkage and draft must be built into the
drawing. (b-c) Patterns have been mounted on plates equipped with pins for alignment. Note the presence of core
prints designed to hold the core in place. (d-e) Core boxes produce core halves, which are pasted together. The
cores will be used to produce the hollow area of the part shown in (a). (f) The cope half of the mold is assembled
by securing the cope pattern plate to the flask with aligning pins and attaching inserts to form the sprue and risers.
Continued on next slide.
Sequence of Operations for Sand-Casting, Cont.
(g) The flask is rammed with sand and rthe plate and inserts are removed. (h) The drag half is produced in a
similar manner with the pattern inserted. A bottom board is placed below the drag and aligned with pins. (i)
The pattern , flask, and bottom board are inverted; and the pattern is withdrawn, leaving the appropriate
imprint. (j) The core is set in place within the drag cavity. (k) The mold is closed by placing the cope on top
of the drag and securing the assembly with pins. The flasks the are subjected to pressure to counteract
buoyant forces in the liquid, which might lift the cope. (l) After the metal solidifies, the casting is removed
from the mold. (m) The sprue and risers are cut off and recycled, and the casting is cleaned, inspected, and
heat treated (when necessary).