Section 3.

Castings

Rev. 4
8/20/01
 Overview
Casting Fundamentals
Pouring and Feeding Castings
Foundry Technology
Inherent Discontinuities
Part 1- Casting Fundamentals
 The Casting Process
Starts with a pattern representing the
finished part.
A mold is constructed from the pattern.

PATTERN

PATTERN IN SOLID MOLD

 The Casting Process
The mold cavity is filled with molten
material.
After soldification, the mold is opened
and excess metal removed.

COMPLETED CASTING WITH

ATTACHED GATING SYSTEM

MOLD CAVITY WITH GATING SYSTEM

 The Casting Process
Process is then checked by inspection.
 Solidification
First Phase:
Heat is given up to the mold material.
Outside liquid is first to cool.
Crystal growth starts at the surface
 Solidification
Second Phase:
Solidification occurs at a slower rate.
The rate of temperature decrease slows.
Crystals grow in a columnar shape toward
the center of the heavy section of the
casting.
 Solidification
Third Phase:
As the wall thickness of frozen metal
increases, the cooling rate of the remaining
liquid decreases even further.
Grains grow to large size.
 Grain Characteristics
Influenced by cooling rates:
Outside grains: fine equaxed.
Outside grains to center grains: columnar
and dendritic.
Center grains: weakest structure with large
equaxed grains.
 Segregation
Term used to describe the condition
wherein differences in chemical
composition occur during solidification
of a casting or ingot.
Microsegregation: within or around the
grains themselves.
Macrosegregation: across the whole ingot
or casting.
 Shrinkage
Three types:
Shrinkage in the liquid
Shrinkage during the transformation from
liquid to solid (solidification shrinkage)
Shrinkage that occurrs after solidification
takes place (contraction in the solid state)
 Shrinkage

1.1% 1.7% 3%

SHRINKAGE
CAVITY
SHRINK PERCENTAGES APPROXIMATE ONLY FOR CAST IRON

THREE STAGES OF METAL CONTRACTION

 Shrinkage
Shrinkage in the Liquid
Metal is superheated to a temperature
above the melting temperature.
Some superheat is lost during transfer of
the liquid metal from the crucible to the
mold.
Loss of superheat results in contraction
and increased density but usually causes
few serious problems in casting.
 Shrinkage
Solidification Shrinkage
Occurs during the transformation from
liquid to solid.
Localized shrinkage develops random
voids called microporosity or
microshrinkage.
 Shrinkage
Solidification Shrinkage
As gas is evolved before and during
solidification, they may form pocket of their
own or may enter voids to enlarge them.
The evolved gas is usually hydrogen which
may combine with oxygen to form water
vapor.
These randomly dispersed large openings
in the solid metal are called macroporosity.
 Shrinkage
Contraction in the Solid State
Occurs after solidification takes place.
Primary cause of dimensional change.
Part 2- Pouring and Feeding
Castings
 Solidification
Progressive vs. directional solidification
Progressive: freezing of a liquid from the
outside towards the center.
Directional: freezing from one end to the
other end.
 Hot Spots
Focal points for solidification.
Defects are most likely at hot spots
created by section or geometry changes
and where gates and risers have been
connected to the castings.
May disturb good directional
solidification and cause defects.
Usually controlled by proper design.
 Pouring & Pouring Rate
If metal enters the cavity too slowly, it
may freeze before the mold is filled.
If the pouring rate is too high, it will
cause erosion of the mold walls.
 The Gating System
Consists of:
Pouring basin,
Down sprues,
Runners,
Ingates, and
Channels and openings.
 Risers
Wells of materials, attached to the
outside of the casting, supply liquid
metal as needed to compensate for
shrinkage before solidification is
complete
 Chills
Initiate solidification.
Choice of internal chills critical.
Part 3- Foundry Technology
 Sand molding
Green sand
green refers to moisture.
Mixture of sand, clay, and moisture.
Sand grains held together by clay.
Dry Sand.
Elimination of moisture reduces casting
defects.
 Permanent Mold Casting
Permanent Mold Casting
Good accuracies and finishes
Metal molds (mostly cast iron and steel)
used primarily for low melting point alloys
Used most for the shaping of aluminum,
copper, magnesium, and zinc alloys
 Die Casting
Die Casting
Differs from the permanent molds casting
in that pressure is applied to the liquid
metal.
The mold is made of metal, has parting
lines, and is constructed with small draft
angles on the walls.
May be either Hot chamber (low pressure)
or Cold chamber (high casting quality with
good surface finish and high material
properties).
Investment/Precision Casting
Investment/Precision Casting
The working pattern destroyed during
casting a new wax pattern is needed for
every piece cast.
Duplicate parts start with a master pattern.
Process limited to small castings.
High quality at high price.
Part 3- Inherent
Discontinuities
 Inherent Discontinuities
Discontinuities which are related to the
melting and original solidification of the
metal or ingot
 Inherent Discontinuities
Cold Shut
Cause: the meeting of two streams of liquid
metal that do not fuse together
Location: surface or subsurface
Pipe
Cause: an absence of molten metal during
the final solidification process
Location: subsurface
 Inherent Discontinuities
Hot Tears
Cause: restraint from the core or mold
during the cooling process
Location: surface
Blowholes and Porosity
Cause: entrapped gases during the
solidification of metal.
Location: surface or subsurface
 Inherent Discontinuities
Nonmetallic Inclusions
Cause: contaminants introduced during the
casting process
Location: surface or subsurface
Segregation
Cause: localized differences in material
composition
Location: surface or subsurface
 Inherent Discontinuities
Microshrinkage
Cause: withdrawal of the low melting point
constituent from the grain boundaries while
the metal is in a plastic or semi-molten
state
Location: subsurface
Other Inherent Discontinuities
Misruns
Unfused Chaplets