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EAT 227
WEEK 2
METAL CASTING
(c)
(a)
(b
)
(d
)
Introduction
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
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shrinkage
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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.
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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
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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that the pattern can be withdrawn.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.
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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,
or pattern.
Last Updated:May
18, 2016
LMS mold
SEGi College
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METAL CASTING
Permanent Mould Casting
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Shell molding
FIGURE 2-12 Shell-molding
process that uses a fine base
sand mixed with a
thermosetting binder. The
mixture
partially cures and forms a
hard shell upon contact with a
hot match plate (which forms
the cover of the dumpbox
containing the sand mixture).
(E. P. DeGarmo, J. T. Black, R.
A. Kohser, and B. E. Klanecki,
Materials and
Processes in Manufacturing,
of a fine
sand
9th base
ed., Wiley,
Newand
York, a
pattern 2003,
and forms
p. 308). the cover
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FIGURE 2-16 Low-pressure permanent mold casting in which an inert gas is used to pressurize the molten metal counter to
gravity through a feed tube and into the permanent mold that is placed on top of the pressure vessel. The solidification
path is designed to enable the shrinkage to be fed by the pressurized molten metal. (Courtesy of Amsted Industries).
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Vacuum
casting
permanent
mold
Die Casting
Process:
molten metal is injected into a closed metal die under high
pressure.
pressure is maintained during solidification.
Die is separated and casting ejected
Two types of die casting
Hot chamber
Cold chamber
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Hot-Chamber Die-Casting
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Advantages
No transfer process of the molten metal, as it is melted in the
chamber from which it is injected into the die cavity
Offer fast cycling times
Good strength product
Excellent dimensional precision and surface finish
Disadvantages:
Expensive as the dies are made from hardened hot-worked tool
steels
Requires high production rates to justify the usage
Cannot be used for high melting point metals
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Cold-Chamber Die-Casting
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Employed for die casting of materials that are not suitable for hot
chamber design.
E.g. Al, Mg, Cu
Process:
Metal is melted in a separate furnace and is transported to the die
casting machine.
Molten metal is fed into an unheated chamber.
A mechanical plunger forces the molten metal into die cavity
where the metal solidifies.
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Advantages:
Good strength product
Excellent dimensional accuracy
Excellent surface finish
Disadvantages:
Expensive dies
Requires high production rate to justify the usage
The need to transport molten metals
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Centrifugal casting
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Mould normally made of steel, iron, or graphite and may be coated with a
refractory lining to increase mould life
Mould surfaces can be shaped so that pipes with various outer shapes
including square or polygonal can be cast
Inner surface of casting remains cylindrical because the molten metal is
uniformly distributed by centrifugal forces
Produces hollows cylindrical parts:
Pipes, gun barrels, streetlamp posts, etc.
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characteristics:
Good quality
Dimensional accuracy
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Centrifuging
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Advantages
Able to produce a wide range of cylindrical parts
Good dimensional accuracy
Disadvantages
Shape is limited
Expensive spinning equipment required
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Continuous Casting
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Continuous casting
Continuous casting accounts for about 95% of the world cast steel
These castings take the form of blooms, slabs, and billets
Replaced ingot casting which is still used in some steel plants or for certain
grades of steel
Concept is over 150 years old but continuous casting became widespread in
Europe especially in the 1970s
Perfectly suited to the mini mill concept with electric steel making facilities
and a continuous caster.
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