A H M 531 Casting By: Ahmed Essam Mansour

Introduction

Casting is the process of shaping liquid or viscous materials, to get an

object after flowing that liquid into a mould containing a cavity that has
the shape of the casting.
This process is considered as one of the oldest careers used in the shaping
of materials, it was used since 4000 years before Christ.
Casting is a process that developed a lot since it was known, and we still
can develop it in our coming days.
By casting any thing we can think of can be formed such as transportation
equipment, transportation means and agriculture tools.
Two type of casting can be defined:
1- Casting in iron moulds: which give much more quantities than
the other type gives, it has a great accuracy, and no finishing is
needed for the object after casting it.
2- Casting in sand moulds (Sand casting): Which is the best for
making complicated objects and it is better for being cheap.

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In this project we used sand casting because it is one of the oldest
operations, and it is the most used for casting process, and it suits for iron
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and steel at there high melting temperature.

Objectives:

In this project we aim to learn how to make the mould and use the casting
tools and its equipments (Foundry) to form an object by sand casting and
we will use aluminum as a molten metal. And we will learn about casting
as an important profession in the humanity civilization.

More information about casting:

Types of casting furnaces:
1- Electrical induction furnace; it is the type we used in our project
and It gives a temperature of 2000 c.
2- Crucible furnace.
3- Electric arcs furnace
The past 3 types are always available and they are used for small
quantities of molten metal.

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A H M 531 Casting By: Ahmed Essam Mansour

4- Blast furnace; Which needs special staff and building and it gives
large quantities of molten metal.

About the patterns:

What is Pattern?
A pattern is the object we place inside the mould temporary before
casting, to make the cavity inside it. And then removed so that the
flowing metal takes the shape of the pattern from the empty cavity.

Types of patterns:
1- Wooden Pattern.
2- Aluminum Pattern.
3- Plastic pattern.
4- Metal Pattern.
In our project we used the wooden Pattern.

Pattern allowance:

The allowance is added volume to the pattern so that the object we get
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after finishing is at the volume we wanted and planed for.

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(To get bigger object is better than getting a smaller one )
The allowance of the pattern can be classified into:

1- Machine allowance; It is the amount by which the volume is made

oversize to provide stock for machining.
2- Shrinking allowance; As metals solidifies and cools, it shrinks in
size so the pattern is made larger that the planed object by an
amount called shrinking allowance.
3- (Withdraw) Taper allowance 1-2 mm (to make it easy moving the
pattern out of the mould).

About the Core:

The core is used in casting process in order to make a hole or a cavity in

the casting, (this process is done sometimes to save metal)

Types of the core:

1- Green core: It is taken from the wet sand.
2- Dry core: It is a mixture of sand, seed, cock coal, wood and other
materials

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A H M 531 Casting By: Ahmed Essam Mansour

3- Metal core: It has to be heated by gas before casting so that we

avoid boiling and producing holes in the piece.
NOTE: All cores are dried under a temperature of 400 c.
Cores Defects:
1- The excess sand.
2- The incurrence in collecting the cores.
3- The difference in dimensions and shapes.

About the sand used in molding:

Sand quality:
1- Strength: Which is the ability to maintain the state of the mold and
forming easily in the flask?
2- Permeability: It is the ability of allowing the air and gases to pass
through during and after casting.
3- Thermal stability: It is the resistance of cracking and bucking due
to the stress.
4- Collapsibility: It is the allowable of shrinking without cracking
used.
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5- Reusability: It is if we can use the used sand.

Thesand:
Types of casting Civil Engineering Center
1- Green Sand; The one we have used in our project.
2- Aleppo Sand.
3- Silica Sand.

About the metal we used:

We use aluminum as molten metal.
Its melting degree is 650-700 c
Its shrinkage percent is 2%

Casting testing and inspections:

1- Ultra-Sonic.
2- Hydro Static pressure.
3- Visual inspection.
4- Magnetic particles.
5- X-ray
6- Gamma-Ray
7- Dye penetration.

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A H M 531 Casting By: Ahmed Essam Mansour

Casting Defects:
1- Gas Cavities.
2- Sponge Cavities.
3- Slag Cavities.
4- Cold shrinkage.
5- Hot tears

Tools And Equipments:

A. Green sand
B. Molten Aluminum
C. Wooden Pattern
D. Hand tools (Are discussed in table 1)

ThereA are H M of531

# The Tool Description
1 Rammers 2 types it:
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Small rammer; It is madeCenter
of iron, Used to
pack the sand in side the box flask.
2- Big rammer; It is made of wood, Used to pack
the sand on the surface of the box after adding
the sand.

2 Dust Bag It is used to isolate he pattern from the sand.

3 Sprue Cutter It is the casting column, Used to make a hole in the

sand in order to pour molten aluminum.

4 Swab Pot It is used to wet the sand around the pattern

5 Swap It is a brush used to clean the working area.

6 Bellows It is a hand air pump used to clean extra sand on the

surface of the flask.

7 Trowel It is used to make flat surfaces.

8 Draw spike A screw used to move the pattern from the sand.

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A H M 531 Casting By: Ahmed Essam Mansour

9 Clamps It is used to fix the pattern inside the flask

10 Strike Bar It is a steel ruler used to take measurements.

11 Rapping Bar It is a metal or steel ruler used to make the surface
straight or flat by moving extra sand.

12 Tongue It is used to hold the hot crucible into\out of the

furnace.

13 Holder It is used to hold the crucible holding the molten

metal.

14 Crucible It is the pot where the aluminum melts inside the

furnace. (It can stand 2000 c).

15 Slike It is a spoon used to make a runner in the sand to let

the molten metal spread all over the pattern.

16 Lifter It is a metal instrument used to clean the label after

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finishing work.

17 RiserThe Civil Engineering

It is used Center
to let the gas out during casting, and to
collect the gangue in it and to make the absorbance
avoid the casting.

18 Vent wire It is a thin wire used to make holes to send gases out
while casting.

19 Flask It is made of iron and used to print the pattern in the

sand

20 The Furnace Electric stove used to melt materials.

Table 1

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