Cast

CHAPTER 11
MetalCastingProcesses
KalpakjianSchmid
ManufacturingEngineeringandTechnology 2001PrenticeHall Page111
TABLE 11.1
Process Advantages Limitations
Sand Almostanymetalcast;nolimit Somefinishingrequired;
tosize,shapeorweight;low somewhatcoarsefinish;wide
toolingcost. tolerances.
Shellmold Gooddimensionalaccuracyand Partsizelimited;expensive

surfacefinish;highproduction patternsandequipment
rate. required.
Expendablepattern Mostmetalscastwithnolimit Patternshavelowstrengthand

tosize;complexshapes canbecostlyforlowquantities
Plastermold Intricateshapes;good Limitedtononferrousmetals;
Summary of
dimensionalaccuracyand limitedsizeandvolumeof
finish;lowporosity. production;moldmakingtime
Casting
relativelylong.
Ceramicmold Intricateshapes;close Limitedsize.
Processes
toleranceparts;goodsurface
finish.
Investment Intricateshapes;excellent Partsizelimited;expensive

surfacefinishandaccuracy; patterns,molds,andlabor.
almostanymetalcast.
Permanentmold Goodsurfacefinishand Highmoldcost;limitedshape

dimensionalaccuracy;low andintricacy;notsuitablefor
porosity;highproductionrate. highmeltingpointmetals.
Die Excellentdimensionalaccuracy Diecostishigh;partsize

andsurfacefinish;high limited;usuallylimitedto
productionrate. nonferrousmetals;longlead
time.
Centrifugal Largecylindricalpartswith Equipmentisexpensive;part

goodquality;highproduction shapelimited.
rate.
KalpakjianSchmid
Die-Casting Examples
(a) (b)
Figure11.1(a)ThePolaroidPDC2000digitalcamerawithaAZ91Ddiecast,highpurity
magnesiumcase.(b)TwopiecePolaroidcameracasemadebythehotchamberdiecasting
process.Source:CourtesyofPolaroidCorporationandChicagoWhiteMetalCasting,Inc.
KalpakjianSchmid
General Characteristics of Casting Processes
TABLE 11.2
Typical
Typical Weig ht(kg) surface Sectionthic kness(mm)
materials finish Shape Dimensional
Process cast Minimum Maximum (m,Ra) Porosity* complexity* accuracy* Minimum Maximum
Sand All 0.05 Nolimit 525 4 12 3 3 Nolimit
Shell All 0.05 100+ 13 4 23 2 2
Expendable
mold
pattern All 0.05 Nolimit 520 4 1 2 2 Nolimit
Nonferrous
Plaster
(Al,Mg,Zn,
mold Cu) 0.05 50+ 12 3 12 2 1
All
(Highmelting
Investment pt.) 0.005 100+ 13 3 1 1 1 75
Permanent
mold All 0.5 300 23 23 34 1 2 50
Nonferrous
(Al,Mg,Zn,
Die Cu) <0.05 50 12 12 34 1 0.5 12
Centrifugal All 5000+ 210 12 34 3 2 100
*Relativerating:1best,5worst.
Note :Theseratingsareonlygeneral;significantvariationscanoccur,dependingonthemethodsused.
KalpakjianSchmid
Casting Examples
Figure 11.2 Typical gray-

iron castings used in
automobiles, including
transmission valve body
(left) and hub rotor with
disk-brake cylinder (front).
Source: Courtesy of Central
Foundry Division of General
Motors Corporation.
Figure 11.3 A cast

transmission housing.
KalpakjianSchmid
Sand Mold Features
Figure11.4Schematicillustrationofasandmold,showingvariousfeatures.
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Steps in Sand Casting
Figure 11.5 Outline of production steps in a typical sand-casting operation.
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Pattern Material Characteristics
TABLE 11.3
a
Rating
Characteristic Wood Aluminum Steel Plastic Castiron
Machinability E G F G G
Wearresistance P G E F E
Strength F G E G G
Weightb E G P G P
Repairability E P G F G
Resistanceto:
Corrosionc E E P E P
Swellingc P E E E E
aE,Excellent;G,good;F,fair;P,poor.
bAsafactorinoperatorfatigue.
cBywater.
Source :D.C.EkeyandW.R.Winter,IntroductiontoFoundryTechnology. NewYork.
McGrawHill,1958.
KalpakjianSchmid
Patterns for Sand Casting
Figure 11.6 A typical metal

match-plate pattern used in
sand casting.
Figure 11.7 Taper on patterns for ease

of removal from the sand mold.
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Examples of Sand Cores and Chaplets
Figure 11.8 Examples of sand cores showing core prints and chaplets to support cores.
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Squeeze Heads
Figure 11.9 Various designs
of squeeze heads for mold
making: (a) conventional flat
head; (b) profile head; (c)
equalizing squeeze pistons;
and (d) flexible diaphragm.
Source: Institute of British
Foundrymen. Used with
permission.
KalpakjianSchmid
Vertical Flaskless Molding
Figure 11.10 Vertical flaskless molding. (a) Sand is squeezed between two halves of the pattern. (b)
Assembled molds pass along an assembly line for pouring.
KalpakjianSchmid
Sequence of Operations for Sand Casting
Figure 11.11 Schematic illustration of the sequence of operations for sand casting. Source: Steel
Founders' Society of America. (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)
KalpakjianSchmid
Sequence of Operations for Sand Casting (cont.)
Figure 11.11 (g) The flask is rammed with sand and the plate and inserts are removed. (g) 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 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).
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Surface Roughness for Various Metalworking Processes
Figure 11.12 Surface roughness in casting and other metalworking processes. See also Figs. 22.14 and
26.4 for comparison with other manufacturing processes.
KalpakjianSchmid
Dump-Box Technique
Figure 11.13 A common
method of making shell
molds. Called dump-box
technique, the limitations are
the formation of voids in the
shell and peelback (when
sections of the shell fall off
as the pattern is raised).
Source: ASM International.
KalpakjianSchmid
Composite Molds
Figure 11.14 (a) Schematic illustration of a semipermanent composite mold. Source: Steel
Castings Handbook, 5th ed. Steel Founders' Society of America, 1980. (b) A composite
mold used in casting an aluminum-alloy torque converter. This part was previously cast in
an all-plaster mold. Source: Metals Handbook, vol. 5, 8th ed.
KalpakjianSchmid
Expendable Pattern Casting
Figure 11.15
Schematic
illustration of the
expendable
pattern casting
process, also
known as lost
foam or
evaporative
casting.
KalpakjianSchmid
Ceramic Molds
Figure 11.16 Sequence of operations in
making a ceramic mold. Source: Metals
Handbook, vol. 5, 8th ed.
Figure 11.17 A typical ceramic

mold (Shaw process) for casting
steel dies used in hot forging.
Source: Metals Handbook, vol.
5, 8th ed.
KalpakjianSchmid
Figure 11.18
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:
Investment
Steel Founders'
Society of
Casting
America.
KalpakjianSchmid
Investment Casting of a Rotor
Figure 11.19 Investment casting of an integrally cast rotor for a gas turbine. (a) Wax pattern assembly.
(b) Ceramic shell around wax pattern. (c) Wax is melted out and the mold is filled, under a vacuum,
with molten superalloy. (d) The cast rotor, produced to net or near-net shape. Source: Howmet
Corporation.
KalpakjianSchmid
Investment and Conventionally Cast Rotors
Figure 11.20 Cross-

section and
microstructure of two
rotors: (top)
investment-cast;
(bottom) conventionally
cast. Source: Advanced
Materials and
Processes, October
1990, p. 25 ASM
International
KalpakjianSchmid
Vacuum-Casting Process
Figure 11.21 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: From
R. Blackburn, "Vacuum Casting Goes Commercial," Advanced Materials and Processes,
February 1990, p. 18. ASM International.
KalpakjianSchmid
Pressure Casting
Figure 11.22 (a) The bottom-pressure casting process utilizes graphite molds for the production of steel
railroad wheels. Source: The Griffin Wheel Division of Amsted Industries Incorporated. (b) Gravity-
pouring method of casting a railroad wheel. Note that the pouring basin also serves as a riser. Railroad
wheels can also be manufactured by forging.
KalpakjianSchmid
Hot- and Cold-Chamber Die-Casting
(a) (b)
Figure 11.23 (a) Schematic illustration of the hot-chamber die-casting process. (b) Schematic
illustration of the cold-chamber die-casting process. Source: Courtesy of Foundry Management and
Technology.
KalpakjianSchmid
Cold-Chamber Die-Casting Machine
(a)
Figure 11.24 (a) Schematic illustration of a cold-chamber die-casting machine.

These machines are large compared to the size of the casting because large forces are
required to keep the two halves of the dies closed.
KalpakjianSchmid
Hot-Chamber Die-Casting Machine
(b)
Figure 11.24 (b) 800-ton hot-chamber die-casting machine, DAM 8005 (made
in Germany in 1998). This is the largest hot-chamber machine in the world
and costs about $1.25 million.
KalpakjianSchmid
Die-Casting Die Cavities
Figure 11.25 Various types of cavities in a die-casting die. Source: Courtesy of

American Die Casting Institute.
Figure 11.26 Examples of

cast-in- place inserts in die
casting. (a) Knurled
bushings. (b) Grooved
threaded rod.
KalpakjianSchmid
Properties and Typical Applications of
Common Die-Casting Alloys
TABLE 11.4
Ultimate
tensile Yield Elongation
strength strength in50mm
Alloy (MPa) (MPa) (%) Applications
Aluminum380(3.5Cu8.5Si) 320 160 2.5 Appliances,automotivecomponents,
electricalmotorframesandhousings
13(12Si) 300 150 2.5 Complexshapeswiththinwalls,parts
requiringstrengthatelevated
temperatures
Brass858(60Cu) 380 200 15 Plumbingfiztures,lockhardware,
bushings,ornamentalcastings
MagnesiumAZ91B(9Al0.7Zn) 230 160 3 Powertools,automotiveparts,sporting
goods
ZincNo.3(4Al) 280 10 Automotiveparts,officeequipment,
householdutensils,buildinghardware,
toys
5(4Al1Cu) 320 7 Appliances,automotiveparts,building
hardware,businessequipment
Source :DatafromAmericanDieCastingInstitute
KalpakjianSchmid
Centrifugal Casting Process
Figure 11.27 Schematic

illustration of the centrifugal
casting process. Pipes,
cylinder liners, and similarly
shaped parts can be cast with
this process.
KalpakjianSchmid
Semicentrifugal Casting
Figure 11.28 (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 force.
KalpakjianSchmid
Squeeze-Casting
Figure 11.29 Sequence of operations in the squeeze-casting process. This process combines the
advantages of casting and forging.
KalpakjianSchmid
Single Crystal Casting of Turbine Blades
Figure 11.30 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) B. H. Kear, Scientific American, October 1986; (c) Advanced Materials and
Processes, October 1990, p. 29, ASM International.
(c)
KalpakjianSchmid
Single Crystal Casting
Figure 11.31 Two methods of

crystal growing: (a) crystal
pulling (Czochralski process)
and (b) the floating-zone
method. Crystal growing is
especially important in the
semiconductor industry.
Source: L. H. Van Vlack,
Materials for Engineering.
Addison-Wesley Publishing
Co., Inc., 1982.
KalpakjianSchmid
Melt Spinning
Figure 11.32 Schematic

illustration of melt-spinning to
produce thin strips of
amorphous metal.
KalpakjianSchmid
Types of Melting Furnaces
Figure 11.33 Two types of melting furnaces used in foundries: (a) crucible, and (b) cupola.
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CHAPTER 11

Shellmold Gooddimensionalaccuracyand Partsizelimited;expensive

Expendablepattern Mostmetalscastwithnolimit Patternshavelowstrengthand

Plastermold Intricateshapes;good Limitedtononferrousmetals;

Ceramicmold Intricateshapes;close Limitedsize.

Investment Intricateshapes;excellent Partsizelimited;expensive

Permanentmold Goodsurfacefinishand Highmoldcost;limitedshape

Die Excellentdimensionalaccuracy Diecostishigh;partsize

Centrifugal Largecylindricalpartswith Equipmentisexpensive;part

Figure 11.2 Typical gray-

Figure 11.3 A cast

Figure 11.5 Outline of production steps in a typical sand-casting operation.

Figure 11.6 A typical metal

Figure 11.7 Taper on patterns for ease

Figure 11.17 A typical ceramic

Figure 11.20 Cross-

Figure 11.24 (a) Schematic illustration of a cold-chamber die-casting machine.

Figure 11.25 Various types of cavities in a die-casting die. Source: Courtesy of

Figure 11.26 Examples of

Figure 11.27 Schematic

Figure 11.31 Two methods of

Figure 11.32 Schematic

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