CASTING:

Casting is the process of producing

metal/alloy component parts of desired shapes
by pouring the molten metal /alloy in to a
prepared mould (of that shape) and then
allowing the metal/ alloy to cool and solidify.
The solidified piece of metal/alloy is known as a
casting.
 CASTING PROCESS

Steps involved in casting process

Pattern making.

Mould making

Core making

Melting of metal and pouring

Cooling and solidification

Cleaning of castings and inspection

Steps involved in making a casting:
1. Make the pattern out of wood ,metal or plastic.
2.In case of sand casting select, test prepare the
necessary sand mixtures and core making.
3. With the help of patterns prepare the mould and
necessary cores.
4. Melt the metal/alloy to be cast.
5. Pour the molten metal/alloy into the mould and
remove the casting from the mould after the metal
solidifies.
6. Clean and finish the casting
7. Test and inspect the casting
8. Remove the defects if any
9. Relieve the casting stresses by heat treatment
10. Again inspect the casting
11. The casting is ready for shipping.
 ADVANTAGES OF METAL CASTING :

1. Casting is the one of the oldest and most versatile

manufacturing processes

2. Casting provides the greatest freedom of design in terms of

SHAPE, SIZE and the product QUANTITY.

3. Casting imparts uniform directional properties and better

vibration damping capacity to the cast parts.

4. Casting produces machinable parts.

5. Shapes difficult and un-economical to obtain otherwise may

be achieved through casting process.
6. A product may be cast as one piece there by eliminating the
need of metal joining process.

7. Very heavy and bulky parts (power plants, paper mills, mill
housings) which are otherwise difficult to fabricated may be
cast.

8. Metals (like CAST IRON) difficult to shaped by other mfg. process

may be cast.

9. Castings can be designed for equal distribution of loads( on all

members of a product) and for minimum stress concentration in
order to achieve more strength and increased service life.

10. Casting process can be mechanized and usefully employed for

mass production of castings.
APPLICATIONS OF METAL CASTINGS:
The growing demand of high precision castings and of
has helped considerably in the development of Foundry Industry.
Hardly there is any product, today which does not have one or more cast
components.

A few applications of cast components are

1. Transportation Vehicles.
cast metal parts account for more than

2. Machine tool structures Eg: shaper, slotter, planner beds (cast iron)
3. Turbine vanes
4. Jet engine(air craft) blades.
5. Power generators
6. Mill housings
7. Railway crossings
8. Paper mill stock breaker parts
9. Pump filters and vanes
10. Agriculture parts
11. Sanitary fittings
12. Communication, construction and atomic energy applications etc.
 Patterns:
Pattern: A pattern is a replica of the object to be made by the
casting process, with some modifications as:
• addition of pattern allowances
• provision of core prints
• Elimination of fine details, which can be obtained by
further processing (ex. Threading, recess).
Functions of the Pattern:
• A pattern prepares a mold cavity for the purpose of making
a casting.
• A pattern may contain projections known as core prints if
the casting requires a core and need to be made hollow.
• Patterns properly made and having finished and smooth
surfaces reduce casting defects.
•A properly constructed pattern minimizes the overall cost of
the castings.