1-Casting Processes - Me206 - t111

METAL CASTING-PROCESSES
October 2011
ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh
METAL CASTING STEPS
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TYPICAL CASTING PRODUCTS-1
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TYPICAL CASTING PRODUCTS-2
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Production Steps in Sand-Casting
Figure Outline of production steps in a typical sand-casting operation.

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Engineering Issues

Alloy selection (mechanical properties, fluidity, volumetric shrinkage) Melting method (rate, oxidation, energy use, gas absorption, reaction with crucible materials) Mold material selection (thermal conductivity, strength, rigidity, volatility, refractoriness, permeability, surface finish) Metal delivery system design (desired flow regime, venting, thermal control, skimming, filtering) Solidification and heat loss of the casting (dimensional control, internal shrink porosity, cracks, grain size and general microstructure) Mold removal, trimming, cleaning and inspection
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Metal Casting-Practice

Foundry practice Casting Quality Metals for Casting Product Design Consideration
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FURNACES
Gas Fired Furnace
Induction Furnaces
October 2011 ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh
Electric Resistance Furnace _Melting Aluminum

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Metals for Casting

Ferrous casting alloys: cast iron Ferrous casting alloys: Steel Nonferrous casting alloys
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Introduction to Casting Processes

Casting of Ingot and Shape Casting Casting of Ingot -Continuous Casting Process Major Shape Casting Processes- Classification Expendable Mold/Reusable Pattern A new mold is required for each new casting Production rate is limited Processes: Sand casting (green sand,dry sand, skin dried sand and no bake) processes, Plaster and Ceramic mold casting, Vacuum casting Expendable Mold/Expendable Pattern A new mold and a new pattern is required for each new casting Processes: Investment castings; Lost wax and lost foam Permanent Mold/No pattern Mold is made of durable materials Ideal for a product with a high production rate October 2011 Processes: Permanent ME 206 Manufacturing 1 ( Gravity casting and low 10 Mold Processes casting Dr Anwar K Sheikh pressure castings), Die casting, Centrifugal casting
Continuous-Casting
Please Visit The Following Website Which is An Excellent Web Source For Continuous Casting Processes http://ccc.illinois.edu/introduction/overview.html
http://ccc.illinois.edu/introduction/overview.html Continuous casting transforms molten metal into solid on a continuous basis and includes a variety of important commercial processes. These processes are the most efficient way to solidify large volumes of metal into simple shapes for subsequent processing. Most basic metals are mass-produced using a continuous casting process, including over 500 million tons of steel, 20 million tons of aluminum, and 1 million tons of copper, nickel, and other metals in the world each year. Many different types of continuous casting processes exist. Figure 1 pictures a few of the most important ones. Vertical machines are used to cast aluminum and a few other metals for special applications. Curved machines are used for the majority of steel casting and require bending and / or unbending of the solidifying strand. Horizontal casting features a shorter building and is used occasionally for both nonferrous alloys and steel. Finally, thin strip casting is being pioneered for steel and other metals in low-production markets in order to minimize the amount of rolling required.
Continuous-Casting
http://ccc.illinois.edu/introduction/overview.html
The continuous casting process for steel is shown in Figure 1 (second frame) and the close-up of the upper mold region in Figure 2. In this process, molten steel flows from a ladle, through a tundish into the mold. The tundish holds enough metal to provide a continuous flow to the mold, even during an exchange of ladles, which are supplied periodically from the steelmaking process. The tundish can also serve as a refining vessel to float out detrimental inclusions into the slag layer.
Figure 1
Figure 2
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Continuous Casting
FIGURE 5.15 (a) The continuous-casting process for steel. Typically, the solidified metal descends at a speed of 25mm/s (1 in/s).Note that the platform is about 20 m (65 ft) above ground level. Source: Metalcasters Reference and Guide, American Foundrymans Society. (b) Continuous strip casting of nonferrous metal strip. Source: Hazelett Strip Casting Corp.
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Continuous-Casting
FIGURE 5.15 (a) The continuous-casting process for steel. Note that the platform is about 20 m (65 ft) above ground level. Source: American Foundrymen's Society. (b) Continuous strip casting of nonferrous metal strip. Source: Courtesy of Hazelett Strip-Casting Corp.
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Casting Processes- Shape Casting

PROCESS Sand Shell mold Expendable pattern Plaster mold ADVANTAGES Almost any metal is cast; no limit to size, shape or weight; low tooling cost. Good dimensional accuracy and surface finish; high production rate. Most metals cast with no limit to size; complex shapes Intricate shapes; good dimensional accuracy and finish; low porosity. Intricate shapes; close tolerance parts; good surface finish. Intricate shapes; excellent surface finish and accuracy; almost any metal cast. Good surface finish and dimensional accuracy; low porosity; high production rate. Excellent dimensional accuracy and surface finish; high production rate. Large cylindrical parts with good quality; high production rate. LIMITATIONS Some finishing required; somewhat coarse finishl wide tolerances. Part size limited; expensive patterns and equipment required. Patterns have low strength and can be costly for low quantities. Limited to nonferrous metals; limited size and volume of production; mold making time relatively long. Limited size. Part size limited; expensive patterns, molds, and labor. High mold cost; limited sh ape and intricacy; not suitable for high-meltingpoint metals. Die cost is high; part size limited; usually limited to nonferrous metals; long lead time. Equipment is expensive; part shape limited.
Ceramic mold Investment Permanent mold
Die
Centrifugal
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TABLE 5.8 Casting processes, and their advantages and limitations. ME 206 Manufacturing Processes 1
Dr Anwar K Sheikh
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Expendable Mold Casting/Reusable Pattern
Sand Casting

Shell Molding Vacuum Molding Plaster Molding Ceramic Mold Casting
Green Sand Molds Dry Sand Molds Skin dried Sand Molds No Bake Process Molds
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Sand Casting

Sand mold is used. Cast parts must be cleaned, inspected, heat treated and machined. Patterns and Cores Solid, Split, Match-plate and Cope-and-drag Patterns Cores achieve the internal surface of the part Molds Size of sand The grains of sand held together by a mixture of water and clay in a flask (or flaskless molding)
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Features of a Sand Mold
FIGURE 5.10 A : Schematic illustration of a sand mold, showing various features.

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Mold Features
FIGURE 5.10 Schematic illustration of a typical sand mold showing various features.
MAJOR COMPONENTS OF SAND MOLDS
Two piece molds consist of a cope on top and a drag on the bottom. The seam between them is the parting line. When more than two pieces are used, the additional parts are called cheeks. A pouring basin or pouring cup, into which the molten metal is poured. A sprue, through which the molten metal flows downward.
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MAJOR COMPONENTS OF SAND MOLDS
Gate, is located at the base of the sprue. Molds typically contain a system of gates constructed to minimize turbulence in the molten metal and control flow so that metal is supplied at a rate to adequately supply the critical section thickness of the casting. Gating systems often include passageways called runners.
Risers, supply additional metal to the casting as it shrinks during solidification. Two different types of risers, blind riser and open riser. Cores, are inserts made from sand. They are placed in the mold to form hollow regions or otherwise define the interior surface of the casting. Vents, are placed in molds to carry off gases produced when the molten metal comes into contact with the sand in the molds and cores
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Properties of Sand
The sand should meet four requirements: (i) Refractoriness The ability to withstand high temperature. This is provided by basic nature of sand.
( ii ) Cohesiveness . The ability to retain a given shape when packed in a mold. This is obtained by coating the-sand grains with clays that become cohesive when moistured. (iii) Collapsibility: The ability to permit the metal to shrink after it solidifies. This is obtained by adding cereals or other organic materials that burn out when exposed to the hot metal, thereby reducing the volume of solid bulk and decreasing the strength of restraining sand. (iv) Permeability: The ability to permit air, gases, fumes etc. to escape through it. This is obtained by proper size of sand particles, the amount and types of clay or other bonding agent and the moisture content.
Properties of Sand
Sand casting uses sand for making molds. Sand used in
molding is silica and following are factors which controls its

properties: (i) (ii) Grain size Clay content
(iii) Moisture content (iv) Cereals or organic material content.
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1. Green Sand Molding

It is the most popular and widely used process in the foundry industry. Green sand contains from 2-8% of moisture (water).
Advantages:
(i) This versatile process is applicable to both ferrous and non-ferrous materials. (ii) Can be used to produce intricate molds since it provides for rapid collapsibility. (iii) Most economical of all the molding processes. This is particularly true when only a few castings are to be made. (iv) Sand is reusable with only slight additions to correct for clay.
Limitations:
(i) Not economical on high production rate. (ii) Green sand is porous and tends to crush and shift under the weight of heavy section. (iii) Particularly week in thin sections likes, fins of heat exchanger. (iv) Very hard to withdraw patterns from the mold if the mold shape is complex or with thin section.
2. Dry Sand Molding

After the mold has been made from green sand then the moistures are driven out by heating or by letting the mold stand for a long period of time or by baking at 350-400F until the sand is completely dry. Once the molds are dried they are closed and the molten metal poured into the mold. Advantages: (i) This kind of mold gives a smoother cast surface. (ii) This kind of mold is used for heavy weight casting. (iii) Have more strength and resist erosion. (iv) Good for thin sections and intricate parts. (v) Repeated parts can be made in same pattern section and assembled to complete the full mold. (vi) Since the mold is hard when the pattern is taken out less draft is necessary. (vii) Since the mold is not easily broken up can be used for more casting.
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3. Skin Dried Sand Molding

Sometimes only the surface in contact with the molten metal is dried. This skin drying is done with a torch or may sometimes be accomplished by applying special quick drying materials to the cavity surfaces.
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3. Skin Dried Sand Molding

Sometimes only the surface in contact with the molten metal is dried. This skin drying is done with a torch or may sometimes be accomplished by applying special quick drying materials to the cavity surfaces.
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4. No Bake Process Molds

Various organic and inorganic binders are blended into the sand To bond the grains chemically and provides greater srength. Molds are more accurate dimensionally and better surface finish than Green Sand Molds but more expensive. Drawbacks are: (1) Distortion of the mold is greater, (2)Due to lower collapsibility of the mold ,castings are subjected to hot tears, (3) lower productivity because it considerable time for molds to dry.
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Patterns For Sand Casting

Made of wood, plastics or metals- Type: One piece ,split, match plate,
Figure: A typical metal match-plate pattern used in sand casting.
Figure Taper on patterns for ease of removal from the sand mold.
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Machining Allowance
Figure: Aluminum piston for an internal combustion engine. (a) As cast; (b) after machining.
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Sand Casting Steps

Drag portion of pattern is placed in flask Types of patterns
One piece, split, match plate, and loose piece Materials Wood Patterns Metal Patterns Plastics/Resins Patterns Laminated Object Mfg.(LOM) Patterns Stereolithography (SLA) Patterns Fusion Deposition Modeling (FDM) Styerofoam Patterns for Lost Foam Process
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Sand Casting Steps
Drag is packed with sand Sand characteristics
Refractoriness- Ability to withstand high temperatures Cohesiveness- Ability to retain given shape Permeability- Ability to allow gasses to escape Collapsibility-Ability to allow metal to shrink and free the casting
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Sand Casting Steps
Mold turned over Insert sprue and riser Pack with sand Flask is separated - pattern removed Gates and runners cut into mold Similar process steps performed on cope Cope & drag reassembled Possibly a core is added Molten metal poured into mold Casting solidifies Mold opened..distorted Part removed Post Processing
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Sand Casting
FIGURE 5.16 Schematic illustration of the sequence of operations in sand casting. (a) A mechanical drawing of the part, used to create patterns. (b-c) Patterns 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. (g) The flask is rammed with sand and the plate and inserts are removed. (h) The drag half is produced in a similar manner. (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. (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). Source: Courtesy of Steel Founders' Society of America.
Mold Processing Methods

Hand ramming - low production Jolt and squeeze machines - medium to high production Vertical parted flaskless molding machines - high production Pit molding - large parts example (such as a 36 water valve)
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Sand Casting Advantages & Disadvantages
Advantages General tooling costs are low Sand in most cases can be reused in some form Can handle a wide variety of metals Relatively easy process to obtain net shape or near-net shape
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Sand Casting Advantages & Disadvantages
Disadvantages Part tolerances (+/- ).01 - .015 Poor surface finish Limited design freedom In hand ramming, process can be labor intensive Single use of mold Price per unit costs can be high One mold per batch
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Other Expendable Mold Casting
Shell Molding Vacuum Molding Plaster and Ceramic Mold casting
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Shell Mold Casting

Shell molding is a process for producing simple or complex near net shape castings, maintaining tight tolerances and a high degree of dimensional stability. Shell molding is a method for making high quality castings. These qualities of precision can be obtained in a wider range of alloys and with greater flexibility in design than diecasting and at a lower cost2011 than investment October casting.
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Shell-Molding Process
Mounted Pattern made of Ferrous Metals or Aluminum Heated to 175 -370 C Coated with a parting agent (such as silicone) The mounted pattern is Clamped to a box Box contain sand containi8ng 2.5 to 4.0 % thermosetting binder Sand mixture is blown over the heated pattern Each pattern gives a corresponding a light weight thin walled shell Two shells are joined and clamped together before pouring the molten metal Smooth mold walls with low molten metal flow resistance and smooth surface finish of the cast product Can produce thin sections, sharp corners and small projections
Shell-Molding Process
FIGURE 5.17 Schematic illustration of the shell-molding process, also called the dump-box technique.
Some Products Made by Shell Casting
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ME 206 Manufacturing Processes 1 http://www.paragcasting.com/grey_iron_casting_auto_part.htm Dr Anwar K Sheikh
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A Semipermanent Composite Mold
Operation Sequence of Making a Ceramic Mold
FIGURE 5.18 A Sequence of operations FIGURE Schematic in making a ceramic mold. Source: Metals illustration of a semipermanent Handbook, 8th ed., Vol. 5: Forging and Casting, Materials Park, OH: ASM composite mold. Source: Steel International, 1970. Castings Handbook, 5th ed., Steel Founders Society of October 2011 ME 206 Manufacturing Processes 1 43 Dr Anwar K Sheikh America, 1980.
Caramic Mold Manufacture
FIGURE 5.18 Sequence of operations in making a ceramic mold.
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Vacuum-Casting Process
FIGURE 5.19 Schematic illustration of the vacuum-casting process. Note that the mold has a bottom gate. (a) before and (b) after immersion of the mold into the molten metal. Source: After R. Blackburn.
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Vacuum-Casting Process
FIGURE 5.19 A Schematic illustration of the vacuum-casting process. Note that the mold has a bottom gate. (a) Before and (b) after immersion of the mod into the molten metal. Source: October 2011 ME 206 Manufacturing Processes 1 After R. Blackburn. Dr Anwar K Sheikh
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Expendable Mold Casting/Expendable Pattern
Investment Casting (Lost wax )-For details

See Handout on Lost Wax Process
Expendable Polystyrene (Lost Foam or Full Mold ) -For details See Handout on Lost Foam
Process
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Investment Casting
FIGURE 5.25 Schematic illustration of investment casting (lost-wax process). Castings by this method can be made with very fine detail and from a variety of metals. Source: Steel Founders Society of America.
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Investment Casting Process

Investment casting requires the use of a metal die, wax, ceramic slurry, furnace, molten metal, and any machines needed for sandblasting, cutting, or grinding. The process steps include the following: Pattern creation - The wax patterns are typically injection molded into a metal die and are formed as one piece. Cores may be used to form any internal features on the pattern. Several of these patterns are attached to a central wax gating system (sprue, runners, and risers), to form a tree-like assembly. The gating system forms the channels through which the molten metal will flow to the mold cavity. Mold creation - This "pattern tree" is dipped into a slurry of fine ceramic particles, coated with more coarse particles, and then dried to form a ceramic shell around the patterns and gating system. This process is repeated until the shell is thick enough to withstand the molten metal it will encounter. The shell is then placed into an oven and the wax is melted out leaving a hollow ceramic shell that acts as a one-piece mold, hence the name "lost wax" casting. October 2011 ME 206 Manufacturing Processes 1 49
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Investment Casting Process-Continued
Pouring - The mold is preheated in a furnace to approximately 1000C (1832F) and the molten metal is poured from a ladle into the gating system of the mold, filling the mold cavity. Pouring is typically achieved manually under the force of gravity, but other methods such as vacuum or pressure are sometimes used. Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting. Cooling time depends on the thickness of the part, thickness of the mold, and the material used. Casting removal - After the molten metal has cooled, the mold can be broken and the casting removed. The ceramic mold is typically broken using water jets, but several other methods exist. Once removed, the parts are separated from the gating system by either sawing or cold breaking (using liquid nitrogen). Finishing - Often times, finishing operations such as grinding or sandblasting are used to smooth the part at the gates. Heat treatment is also sometimes used to harden the final part.
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Investment Casting Process After Producing the Wax Patterns
http://www.custompartnet.com/wu/investment-casting
Investment Casting
Process steps Produce master pattern of desired casting Produce master die Produce wax patterns Assemble wax patterns on a common sprue sometimes called a tree Coat tree with an initial investment material Vibrate to remove air and settle material around patterns
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Investment Casting
Process steps continued: Finish coat Allow investment to harden Fire investment to finish hardening process and melt our wax patterns Preheat mold Pour molten metal into mold cavity Allow metal to solidify Remove castings Post processing
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Investment Casting
FIGURE 5.21 Schematic illustration of investment casting (lost wax process). Castings by this method can be made with very fine detail and from a variety of metals. Source: Steel Founders' Society of America.
Advantages & Disadvantages
Advantages
Wide variety of metals can be cast including high temperature alloys Excellent surface finish Good dimensional accuracy () .003 up to Tooling cost average Complex shapes are possible
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Examples of Some Investment Cast Parts
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Investment and Conventional Casting

investment cast
cast conventionally
FIGURE 5.26 The top rotor was investment cast; the lower rotor was cast conventionally. Source: Advanced Materials and Processes, ASM International, October 1990 p. 25.
Evaporative Pattern Casting
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FIGURE 5.20 Schematic illustration of the expendable-pattern casting process, also known as lost-foam or evaporative-pattern casting.
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Lost-Foam Casting of Engine Blocks
FIGURE 5.40 (a) An engine block for a 60-hp 3-cylinder marine engine, produced by the lostfoam casting process; (b) a robot pouring molten aluminum into a flask containing a polystyrene pattern. In the pressurized lost-foam process, the flask is then pressurized to 150 psi (1000 kPa). Source: Courtesy of Mercury Marine
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Permanent Mold Casting

The permanent mold casting process consists of the following steps: Mold preparation - First, the mold is pre-heated to around 300-500F (150-260C) to allow better metal flow and reduce defects. Then, a ceramic coating is applied to the mold cavity surfaces to facilitate part removal and increase the mold lifetime. Mold assembly - The mold consists of at least two parts - the two mold halves and any cores used to form complex features. Such cores are typically made from iron or steel, but expendable sand cores are sometimes used. In this step, the cores are inserted and the mold halves are clamped together. Pouring - The molten metal is poured at a slow rate from a ladle into the mold through a sprue at the top of the mold. The metal flows through a runner system and enters the mold cavity. Cooling - The molten metal is allowed to cool and solidify in the mold. Mold opening - After the metal has solidified, the two mold halves are opened and the casting is removed. Trimming - During cooling, the metal in the runner system and sprue solidify attached to the casting. This excess material is now October 2011 ME 206 Manufacturing Processes 1 cut away. 60
Dr Anwar K Sheikh
Permanent Mold Casting ProcessMultiple Use Mold-No Pattern
A metal (steel or cast iron) mold made of two sections Al, Mg, Copper alloy and Cast Iron Basic Steps Preheated Mold (metals to flow) Coatings are sprayed Pour and solidify Mold is open and casting is removed Advantage - Good surface finish, Close dimensional control and Fine grain due to rapid solidification. Disadvantage Simple geometric part, expensive mold. Example - automobile piston, pump bodies castings for aircraft and missiles.
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Permanent Mold Casting ProcessMultiple Use Mold -No Pattern
Disadvantages Majority of molds use low-melt alloys Mold costs can be high Mold life varies Temperature of alloy being poured Mold material Mold temperature Thermal shock Mold configuration
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Permanent Mold Casting (Gravity)
The tool Molds are machined from tool steels and can have metal retractable cores The Process Molds are pre-heated Molten metal is poured into the molds and enters the mold cavity through the gate under gravity feed. After solidification.mold is opened and part removed
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Permanent Mold Casting (Gravity)
Metals Aluminum, Zinc, Magnesium, Copper,and Brass Alloys Tolerances () .012 first inch (add .002 per inch) Wall section .125 Normal Minimum Section Thickness: Aluminum:.100" for small areas, up to 3/16" or more for large areas. Copper Base: .060" Ferrous: 3/16" for small areas, 1/4" normal.
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Advantages
Generally the same as all other multiple use moldsand mold life is about 25,000 + cycles
Some limitations in complexity of mold and fine section detail may be limited
Variations of Permanent Mold Casting -Low Pressure Permanent Mold Casting:
Low Pressure Casting - Molten metal forced by gas pressure. Low Pressure Permanent Mold Casting is yet another variation of the permanent mold casting. Here, instead of using gravity to assist in the metal pour and flow in the mold, a low pressure of upto 1 atmosphere gas is applied to the molten metal. This maintenance of pressure on the melt causes complete fill of the mold and compensates for any shrinkage on cooling. Thin wall castings can be made. Mechanical properties are about 5 % superior to permanent mold casting. Since no riser is used (unlike a regular casting), the yield is generally higher since the metal in the pressurized feed tube is still molten and the mold is ready for the next shot right away.
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Variations of Permanent Mold CastingVacuum Permanent Mold Casting:

Vacuum Permanent Mold Casting is yet another variation of the permanent mold casting. This is similar to the low-pressure permanent mold casting, where a vacuum is used instead of a pressure. Thin wall castings can be made as in the low-pressure permanent mold casting. In addition, the yields are high since no risers are used. Since vacuum is used instead, the purity of the metal is maintained. The mechanical properties of the casting are 10 to 15 % superior to the traditional permanent mold casting. Castings range in size from 200 g to 4.5 kg (6 oz to 10 lb).
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FIGURE 5.23 The pressure casting process, utilizing graphite molds for the production of steel railroad wheels. Source: Griffin Wheel Division of Amsted Industries Incorporated.
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Die Casting
Molds are made of tool steel, mold steel, maraging steel, tungsten and molybdenum. Single or multiple cavity Lubricants and Ejector pins to free the parts Venting holes and passageways in die Formation of flash that needs to be trimmed Advantages High production, Economical, close tolerance, good surface finish, thin sections, rapid cooling
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Die Casting
The molten metal is injected into mold cavity (die) under high pressure (7-350MPa).Pressure maintained during solidification. Hot Chamber (Pressure of 7 to 35MPa) The injection system is submerged under the molten metals (low melting point metals such as lead, zinc, tin and magnesium) Cold Chamber (Pressure of 14 to 140MPa) External melting container (in addition aluminum, brass and magnesium)
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Pressure & Hot-Chamber Die Casting
FIGURE 5.24 Schematic illustration of the hotchamber die-casting process.
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Cold Chamber
Cold Chamber

Higher temperature alloys (aluminum and magnesium) Metal is melted in a separate furnace and transported to the machine Measured quantity of metal is forced into the mold by a hydraulic or mechanical plunger (can be a double plunger system for productivity)
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Cold-Chamber Die Casting
FIGURE 5.25 Schematic illustration of the coldchamber die-casting process. These machines are large compared to the size of the casting, because high forces are required to keep the two halves of the die closed under pressure.
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Advantages

Fine section detail (.003) Excellent dimensional accuracy (+/- .002) High production rates Excellent surface finish Control of process temperatures Extended mold life Limited part defects
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Disadvantages

Part size (up to 25 lbs.) Limited to low melt alloys Tooling Costs
For More details See Handout on Die Casting
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Properties of Die-Casting Alloys
TABLE 5.6 Properties and typical applications of common die-casting alloys.

Centrifugal casting
True centrifugal casting Semicentrifugal casting Centrifuge casting
For details See Handout on Centrifugal Casting
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Centrifugal Casting
Centrifugal casting, sometimes called rotocasting, is a metal casting process that uses centrifugal force to form cylindrical parts. This differs from most metal casting processes, which use gravity or pressure to fill the mold. In centrifugal casting, a permanent mold made from steel, cast iron, or graphite is typically used. However, the use of expendable sand molds is also possible. The casting process is usually performed on a horizontal centrifugal casting machine (vertical machines are also available) and includes the following steps:
FIGURE 5.26 Schematic illustration of the centrifugal casting process. Pipes, cylinder liners, and similarly shaped hollow parts can be cast by this process.
Centrifugal Casting
A Centrifugal Casting System

Centrifugal Casting
Mold preparation - The walls of a cylindrical mold are first coated with a refractory ceramic coating, which involves a few steps (application, rotation, drying, and baking). Once prepared and secured, the mold is rotated about its axis at high speeds (300-3000 RPM), typically around 1000 RPM. Pouring - Molten metal is poured directly into the rotating mold, without the use of runners or a gating system. The centrifugal force drives the material towards the mold walls as the mold fills. Cooling - With all of the molten metal in the mold, the mold remains spinning as the metal cools. Cooling begins quickly at the mold walls and proceeds inwards. Casting removal - After the casting has cooled and solidified, the rotation is stopped and the casting can be removed. Finishing - While the centrifugal force drives the dense metal to the mold walls, any less dense impurities or bubbles flow to the inner surface of the casting. As a result, secondary processes such as machining, grinding, or sand-blasting, are required to clean and smooth the inner diameter of the part.
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Centrifugal Casting Process Continued

Centrifugal casting is used to produce axi-symmetric parts, such as cylinders or disks, which are typically hollow. Due to the high centrifugal forces, these parts have a very fine grain on the outer surface and possess mechanical properties approximately 30% greater than parts formed with static casting methods. These parts may be cast from ferrous metals such as low alloy steel, stainless steel, and iron, or from nonferrous alloys such as aluminum, bronze, copper, magnesium, and nickel. Centrifugal casting is performed in wide variety of industries, including aerospace, industrial, marine, and power transmission. Typical parts include bearings, bushings, coils, cylinder liners, nozzles, pipes/tubes, pressure vessels, pulleys, rings, and wheels.
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Centrifugal Casting With Vertical Axis of Rotation
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Capabilities of Centrifugal Casting

Typical Feasible Shapes: Production quantity:100 Thin-walled: Cylindrical 10000 Solid: CylindricalThin-walled: Lead time:Weeks or Days Complex Advantages:Can form very Solid: Complex large parts Part size: Good mechanical properties Diameter: 1 - 120 in. Good surface finish and Length: Up to 50 ft. Weight: Up to 5 tons accuracy Materials :Metals Low equipment cost Alloy Steel, Carbon Steel Low labor cost Cast Iron, Stainless Steel Little scrap generated Aluminum,Copper,Nickel Disadvantages:Limited to Surface finish Ra: (Typical) cylindrical parts 63 - 500 in (Feasible) 32 - 500 Secondary machining is often in required for inner diameter Wall thickness: (Typical) Long lead time possible 0.1 - 5.0 in.(Feasible) 0.1 - 5.0 in. Applications:Pipes, wheels, Tolerance: (Typical) 0.01 in. (Feasible) 0.002 in. pulleys, nozzles October 2011 ME 206 Manufacturing Processes 1
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Semicentrifugal Casting
FIGURE 5.27 (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes can be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are placed at the periphery of the machine, and the molten metal is forced into the molds by centrifugal forces.
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Variations of Permanent Mold Casting Slush Casting
Slush Casting is a special type of permanent mold casting, where the molten metal is not allowed to completely solidify. After the desired wall thickness is obtained, the not yet solidified molten metal is poured out by mold inversion before the castings have completely solidified which allows molten metal to pour out and leave a hollow-shell casting. This is useful for making hollow ornamental objects such as candlesticks, lamps, statues etc.
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Squeeze-Casting
Squeeze casting, also known as liquid metal forging, is a combination of casting and forging process. The molten metal is poured into the bottom half of the preheated die. As the metal starts solidifying, the upper half closes the die and applies pressure during the solidification process. The amount of pressure thus applied is significantly less than used in forging, and parts of great detail can be produced. Coring can be used with this process to form holes and recesses. The porosity is low and the mechanical properties are improved.
Both ferrous and non-ferrous materials can be produced using this method.
Squeeze-Casting
FIGURE 5.28 Sequence of operations in the squeeze-casting process. This process combines the advantages of casting and forging.
Directional/Single Crystal Solidification

Directional/single crystal Direction solidification results in a structure with grain boundaries parallel to the direction of solidification. Single crystal castings have no internal grain boundaries. Both directional and single crystal castings can be produced by having a surface for heat extraction contacting the molten metal. For directional solidification this can be a simple plate, whereas a single crystal would have a grain selector or seed crystal to produce the desired orientation.
October 2011
Diagram of a single crystal casting mold.

86
Turbine Blade Casting
FIGURE 5.29 Methods of casting turbine blades: (a) directional solidification; (b) method to produce a single-crystal blade; and (c) a single-crystal blade with the constriction portion still attached. Source: (a) and (b) After B.H. Kear, (c) Courtesy of ASM International.
October 2011
87
Crystal Growing
FIGURE 5.30 Two methods of crystal growing: (a) crystal pulling (Czochralski process) and (b) floating-zone method. Crystal growing is especially important in the semiconductor industry. (c) A single-crystal silicon ingot produced by the Czochralski process. Source: Courtesy of Intel Corp.
Melt-Spinning Process
FIGURE 5.31 (a) Schematic illustration of the melt-spinning process to produce thin strips of amorphous metal. (b) Photograph of nickel-alloy production through melt-spinning. Source: Courtesy of Siemens AG.
October 2011
89

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METAL CASTING-PROCESSES

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

METAL CASTING STEPS

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

TYPICAL CASTING PRODUCTS-1

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

TYPICAL CASTING PRODUCTS-2

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Production Steps in Sand-Casting

Figure Outline of production steps in a typical sand-casting operation.

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Gas Fired Furnace

Electric Resistance Furnace _Melting Aluminum

Metals for Casting

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Introduction to Casting Processes

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Casting Processes- Shape Casting

Ceramic mold Investment Permanent mold

Expendable Mold Casting/Reusable Pattern

Shell Molding Vacuum Molding Plaster Molding Ceramic Mold Casting

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Features of a Sand Mold

FIGURE 5.10 A : Schematic illustration of a sand mold, showing various features.

MAJOR COMPONENTS OF SAND MOLDS

MAJOR COMPONENTS OF SAND MOLDS

molding is silica and following are factors which controls its

(iii) Moisture content (iv) Cereals or organic material content.

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

1. Green Sand Molding

2. Dry Sand Molding

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

3. Skin Dried Sand Molding

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

3. Skin Dried Sand Molding

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

4. No Bake Process Molds

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Patterns For Sand Casting

Figure: A typical metal match-plate pattern used in sand casting.

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Sand Casting Steps

Drag portion of pattern is placed in flask Types of patterns

Sand Casting Steps

Drag is packed with sand Sand characteristics

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Sand Casting Steps

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Mold Processing Methods

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Sand Casting Advantages & Disadvantages

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Sand Casting Advantages & Disadvantages

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Other Expendable Mold Casting

Shell Molding Vacuum Molding Plaster and Ceramic Mold casting

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh

Shell Mold Casting

ME 206 Manufacturing Processes 1 Dr Anwar K Sheikh