Castingg

MS 2260 PROSES
MANUFAKTUR I
Mechanical and
Production Engineering
Week - 3
Day Topic Sub Topic Ref.
 Solidification of metal
Fundamental  Fluid Flow
1 Chp. 10
of casting  Heat Transfer
 Defect
MS 2260
MANUFACTURING PROCESSES I
Fundamental
of Casting
Facilitator:
Dr. Ir. Tri Prakosa, M. Eng.
Mechanical and
Metal Casting Product
Metal casting processes
Metal Casting Processes Foundries
Expendable mold Permanent mold Single crystal growing
Composite Mold
Introduction
Pengantar
Pada dasarnya proses casting (pengecoran) melibatkan :
1. Penuangan logam cair (pouring molten metal) ke dalam cetakan (mold)

2. Proses pembekuan (memadatkan, mengeraskan; solidify).
3. Memisahkan produk dari cetakan
Hal-hal yang perlu diperhatikan dalam proses pengecoran :
1. Aliran logam cair ke dalam rongga cetak (mold cavity)

2. Pemadatan dan pendinginan logam di dalam cetakan.
3. Pengaruh dari material cetakan.
Solidifikasi Logam
Proses solidifikasi logam dipengaruhi oleh :
1. Ukuran (size)
2. Bentuk (shape)
3. Keseragaman (uniformity)
4. Komposisi kimia (chemical composition)
Faktor lain yang perlu diperhatikan :
1. Jenis logam
2. Sifat panas (thermal properties) logam dan cetakan
3. Hubungan geometrik antara volume dan luas permukaan antara produk
dan betuk cetakan.
Solidifikasi Logam Murni
(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
Schematic illustration of
three cast structures of
metals solidified in a square
mold:
(a) pure metals;
(b) solid-solution alloys; and
(c) structure obtained by
using nucleating agents.
Source: After G. W. Form, J. F.

Wallace, J. L. Walker, and A. Cibula
Logam yang
bersentuhan dengan
dinding cetakan akan
memadat lebih cepat
dan membentuk
solidified skin atau shell
yang terdiri dari fine
equiaxed grains.
Butir kristal tumbuh

dengan arah
berlawanan dengan
arah transfer panas
(heat transfer)
membentuk columnar
grain (butir berbentuk
kolom)
Bila perpindahan panas
tidak lagi terjadi maka
butir kristal akan tubuh
berbentuk equiaxial dan
besar (coarse equiaxed
grains)
Schematic illustration of three

cast structures of metals
solidified in a square mold:
(a) pure metals;
(b) solid-solution alloys; and
(c) structure obtained by using
nucleating agents
Solidification: Pure Metals
-
 Because of the chilling

action of the mold wall, a
thin skin of solid metal is
initially formed at interface
immediately after pouring.
 The skin formed initially has
equi-axed, fine grained and
randomly oriented structure.
This is because of rapid
cooling.
Characteristic of grain structure in a casting of a pure metal, showing randomly
oriented grains of small size near the mold wall, and large columnar grains
oriented toward the center of the casing
-
 As freezing proceeds, the

grains grow inwardly, away
from heat flow direction, as
needles or spine of solid
metal.

-
 On further growth of spine,

lateral branches are formed,
and as these branches
grow further branches are
formed at right angle to the
first branches. This type of
growth is called dendritic
growth.

-
 The dendritic grains are

coarse, columnar and
aligned towards the center
of casting.

Solidification: Most Alloys
 Most alloys freeze at range of temperature
rather than at a single temperature.
(a) Phase diagram for a copper-nickel alloy system and

(b) associated cooling curve for a 50%Ni-50%Cu composition during casting
 Freezing begins from liquidus temperature and
completes at solidus temperature.

 The cooling begins in the same manner as that
in pure metals; a thin skin is formed at the
interface of mold and makes shell as freezing
proceeds.

 The dendrites begin to form
with freezing. However, Pure
due to large temperature metal
spread between solidus
and liquidus, the earlier
portion of dendritic grains Fe
extract higher % of
elements from liquid
Fe-Ni
solution than the portion of Alloy
grain formed later.
Characteristic of grain structure in an alloy casting, showing segregation of alloying

components in the center of casting
 As a result, the molten
metal in the center of mold Pure
cavity depletes from the metal
elements and hence forms
a different structure (see
Fig). Fe
Fe-Ni
Alloy
Characteristic of grain structure in an alloy casting, showing segregation of alloying

components in the center of casting
Solidifikasi Paduan (Alloys)
Schematic
illustration of alloy
solidification and
temperature
distribution in the
solidifying metal.
Note the formation of
dendrites in the
mushy zone.
Solidification of Iron
and Carbon Steels
Figure 10.5 (a) Solidification patterns for gray cast iron in a 180-mm (7-in.) square casting. Note that after 11
minutes of cooling, dendrites reach each other, but the casting is still mushy throughout. It takes about two hours
for this casting to solidify completely. (b) Solidification of carbon steels in sand and chill (metal) molds. Note the
difference in solidification patterns as the carbon content increases. Source: After H. F. Bishop and W. S. Pellini
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Basic Types of Cast Structures
Columnar Dendritic Equiaxed Dendritic Equiaxed Non-Dendritic
Figure 10.6 Schematic illustration of three basic types of cast structures: (a) columnar
dendritic; (b) equiaxed dendritic; and (c) equiaxed nondendritic. Source: Courtesy of D. Apelian
Cast Structures
higher concentration
of alloying elements
Single Phase Two Phases
Figure 10.7 Schematic illustration of cast structures in (a) plane front, single
phase, and (b) plane front, two phase. Source: Courtesy of D. Apelian
Efek laju pendinginan
1. Laju pendinginan lambat (slow cooling rate)  coarse dendritic
structure with large spacing between dendrite arms.
2. Laju pendingan cepat (higher cooling rate)  finer with smaller
dendrite arm spacing.
3. Laju pendinginan lebih cepat (still higher cooling rate) 
amorphous
 Struktur yang terbentuk dan ukuran butir yang dihasilkan akan

mempengaruhi sifat (properties) produk pengecoran.
 Ukuran butir mengecil  strength dan ductility meningkat,
microporosity berkurang, kecendrungan untuk terjadi retak
selama solidifikasi berkurang.
 Anisotropic properties, merupakan kelemahan sifat coran akibat
ketidak seragaman ukuran butir dan ketidakmeratan distribusi
ukuran butir.
Aliran Fluida (fluid flow)
Aliran Fluida (fluid flow) -1
Keberhasilan proses casting bergantung pada

kemampuan dalam merencanakan dan mengendalikan
proses solidifikasi demi menjamin kecukupan material
cair memasuki cetakan.
 Bernoulli’s Theorem
 Mass continuity
 Sprue Design
 Modeling
 Flow characteristic
Aliran Fluida (fluid flow) - 2
 Bernoulli’s Theorem
𝑝1 𝑣12 𝑝2 𝑣22
ℎ1 + + = ℎ2 + + +𝑓
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔
 Mass Continuity
𝑄 = 𝐴1 𝑣1 = 𝐴2 𝑣2
 Sprue Design
𝐴1 ℎ2
=
𝐴2 ℎ1
Aliran Fluida (fluid flow) - 3
 Modeling (of mold filling)
Velocity of molten metal leaving the gate:
𝑣 = 𝑐 2𝑔ℎ
c: friction factor 0 – 1
h: distance from the sprue h
base to the metal surface

 Flow characteristic
𝑣𝐷𝜌
𝑅𝑒 =
𝜂 Less than 2000 : laminar flow
2000 – 20 000 : mixed flow
More than 20 000 : turbulent flow
High Melt Temperature
 Chemical Activity
3000° C
 High Latent Heat Tungsten Carbide, WC,
Silicon Carbide, SiC Cubic Zirconia, ZrO2
 Handling Molybdenum
 Off-gassing 2000° C
Alumina Al2O3
Platinum, Pt
Titanium, Ti
IronFE, Plain Carbon Steels, low alloy,
stainless Silicon, Si
Nickel, Ni
Nickel Allows
1000° C Copper, Cu, Bronze, Brass
Aluminum
Magnesium Nylon
Zinc, Zn Acetal
PTFE (Teflon)
Tin, Sn
0° C HDPE
Mold Filling
 Bernouli’s Equation:
𝑝 𝑣2
ℎ+ + = 𝐶𝑜𝑛𝑠𝑡.
𝜌𝑔 2𝑔
 Reynolds Number:
h
𝑣𝐷𝜌
𝑅𝑒 =
𝜂
 Short filling times
 Potential Turbulence
 (see p. 273 … Kalpakjian
Reynolds Number
in Gating System
 Between 2000  Re  20,000,  mixture of
laminar and turbulent flow
 harmless in gating systems
 Re  20,000  severe turbulence
 significant air entrainment
 formation of dross from the reaction of the liquid
metal with air and other gases.
Reynolds Number
in Gating System
 Techniques for minimizing turbulence:
 avoidance of sudden changes in flow direction
and in the geometry of channel cross sections in
gating system design.
Mold Filling Example (1 of 2)
Mold Filling Example (2 of 2)
Fluiditas Logam Cair
 Kemampuan logam cair untuk mengisi rongga cetak disebut fluiditas (fluidity).
 Fluiditas dipengaruhi oleh dua faktor dasar :
• Karakteristik material logam cair
• Parameter pengecoran (casting parameter)
 Karakteristik material yang mempengaruhi fluiditas:
• Viskositas
• Tegangan permukaan (surface tension)
• Inclusion
• Pola solidifikasi paduan (solidification pattern of alloy)
• Desain cetakan (mold design)
• Material cetakan dan karakteristik permukaannya
• Derajad super panas (degree of superheat)
• Laju penuangan (rate of pouring)
• Heat Transfer (perpindahan panas)
  Castability : kemudahan suatu logam untuk dicor dengan mengahasilkan

produk dengan kualitas yang baik
Perpindahan Panas
 Siklus perpindahan panas lengkap ( penuangan logam, solidifikasi,
pendinginan ke temperatur ruang ) merupakan suatu hal yang penting
dalam proses pengecoran.
 Aliran panas (heat flow) pada suatu lokasi yang berbeda pada suatu
sistem merupakan fenomena yang kompleks dan dipengaruhi oleh
beberapa faktor yang berhubungan dengan:
 Material coran,
 Material cetakan
 Parameter proses.
 Contoh kasus : Pada pengecoran dengan ketebalan (dinding) produk

yang tipis, laju aliran material harus cukup tinggi untuk menghindari
pendinginan dan solidifikasi prematur (premature chilling and
solidication). Sementara itu kecepatan aliran yang terlalu tinggi perlu
dihindari untuk mencegah terjadinya turbulensi.
(bergantung pada : material coran, material cetakan dan parameter

proses)
Distribusi temperatur
 Distribusi temperatur
pada “interface”
cetakan dan logam
cair terlihat bahwa
panas dari logam cair
dilepaskan ke udara
sekitar melalui
dinding cetakan.
Distribusi temperatur
 Temperatur turun
secara drastis (drop)
pada permukaan
udara-cetakan dan
permukaan cetakan-
logam cair, hal ini
disebabkan adanya
lapisan batas
(boundary layers) dan
ketidaksempurnaan
kotak pada kedua
permukaan tersebut
Waktu Solidifikasi
Pada saat awal proses solidifikasi, akan terbentuk lapisan tipis pada
dinding cetakan yang relatif lebih “dingin” , yang selanjutnya (seiring
dengan waktu) ketebalannya akan terus bertambah.
Solidified skin on a steel casting. The remaining molten metal is poured out at the times
indicated in the figure. Hollow ornamental and decorative objects are made by a process
called slush casting, which is based on this principle. Source: After H. F. Taylor, J. Wulff,
and M. C. Flemings
Waktu Solidifikasi
Pada durasi hasil coran setelah 1 menit : terlihat bahwa pada posisi A
dinding coran lebih tipis dari pada posisi B  Mengapa ?
FIGURE I0.11 Solidified skin on a steel casting. The remaining molten metal is poured out at the times
indicated in the figure. Hollow ornamental and decorative objects are made by a process called slush
casting, which is based on this principle. Source: After H.F. Taylor, J. Wulff, and M.C. Flemings.
Waktu Solidifikasi
 The effects of mold geometry and elapsed time on skin

thickness and shape are shown in Fig. 10.11.
Waktu Solidifikasi
 As illustrated, the unsolidified molten metal has been

poured from the mold at different time intervals ranging
from 5 seconds to 6 minutes.
Waktu Solidifikasi
 Note that (as expected) the skin thickness increases

with elapsed time, and the skin is thinner at internal
angles (location A in the figure) than at external angles
(location B).
Waktu Solidifikasi
 The latter condition is caused by slower cooling at

internal angles than at external angles.
Waktu Solidifikasi
 Selama tahap awal pembekuan, lapisan tipis

mulai terbentuk pada dinding cetakan yang
relatif masih dingin, dan seiring berjalannya
waktu, ketebalannya meningkat (gambar
sebelumnya).
 Pada cetakan dengan dinding datar, ketebalan
ini sebanding dengan akar kuadrat waktu
solidifikasi.
 Dengan demikian, menggandakan waktu akan
membuat ketebalan menjadi 2 = 1,41 kali atau
41% lebih tebal.
Waktu Solidifikasi (2)
 Waktu solidifikasi merupakan fungsi dari volume coran
dan luas permukaan coran (Chvorinov’s Rule) :
𝑉𝑜𝑙𝑢𝑚𝑒 𝑛
Solidification Time = C
𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝐴𝑟𝑒𝑎
 C merupakan konstanta yang mewakili :

 Material cetakan
 Sifat logam coran
 Temperatur
 n , parameter yang nilainya antara 1,5 s.d 2
 Mana yang lebih cepat menjadi padat dan dingin :

– Bola besar atau bola kecil ?  mengapa ?
Solidification Times
for Various Shapes
 Three metal pieces being cast have the same
volume, but different shapes:
1. a sphere
2. a cube
3. a cylinder
with its height equal to its diameter.
 Which piece will solidify the fastest, and which
one the slowest? Assume that n = 2.
for Various Shapes
Solution:
 The volume of the piece is taken as unity.
 Thus from Eq. (10.7),
1
Solidification time ∝ 2
Surface Area
for Various Shapes
Solution:
 Sphere:
1/3
4 3
𝑉= 𝜋𝑟 3 𝑟=
3 4𝜋
2/3
3
𝐴= 4𝜋𝑟 2 = 4𝜋 = 𝟒. 𝟖𝟒
4𝜋
 Cube
𝑉 = 𝑎3 , 𝑎 = 1 𝐴 = 6𝑎2 = 𝟔
for Various Shapes
Solution:
 Cylinder:
1/3
1
𝑉= 𝜋𝑟 2 ℎ = 2𝜋𝑟 3 𝑟=
2𝜋
2/3
1
𝐴= 2𝜋𝑟 2 + 2𝜋𝑟ℎ = 6𝜋𝑟 2 = 6𝜋 = 𝟓. 𝟓𝟒
2𝜋
for Various Shapes
Solution:
 The respective solidification times are therefore
𝑡𝑠𝑝ℎ𝑒𝑟𝑒 = 0.043𝐶
𝑡𝑐𝑢𝑏𝑒 = 0.028𝐶
𝑡𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 0.033𝐶
Hence:
 the cube-shaped piece will solidify the fastest,
 the spherical piece will solidify the slowest
Penyusutan (shrinkage) - 1
 Logam akan menyusut (shrinkage) selama

proses solidifikasi berlangsung dan saat terjadi
penurunan temperatur ke temperatur ruang.
 Penyusutan mengakibatkan terjadinya
perubahan ukuran dan bentuk, dan terkadang
coran menjadi melengkung atau
bergelombang (warping) dan terjadi retakan
(cracking).
 Penyusutan terjadi akibat dari beberapa hal

berikut :
 Kontraksi logam cair pada saat terjadi pendinginan
sebelum solidifikasi
 Kontraksi logam selama perubahan fasa dari cair
menjadi padat.
 Kontraksi akibat temperatur drop ke temperatur
ruang pada logam sedang yang mengalami
solidifikasi
?
 When liquid bismuth freezes, it expands

rather than contracts because it forms a
crystalline structure similar to water.
 Four other elements expand when they freeze:
 Silicon,
 Gallium,
 Antimony
 Germanium
 Gray cast iron expands during solidification

 The reason is that graphite has a relatively high
specific volume, and when it precipitates as
graphite flakes during solidification of the gray
cast iron, it causes a net expansion of the
metal.
Cacat pada coran (defect) (1)
 Menurut The International Committee of

Foundary Technical Association, terdapat
tujuh kelompok dasar cacat coran :
A. – Metallic Projection
B. – Cavities
C. – Discontinuities
D. – Defective
E. – incomplete casting
F. – Incorrect dimension or shape
G. – Inclusions
Compiled By Agung Wibowo

A  Metallic projections
 Metallic projections, consisting of: fins, flash, or

projections such as swells and rough surfaces.
B  Cavities
 Cavities, consisting of:

 rounded cavities
 rough internal cavities
 exposed cavities
including:
 blowholes
 pinholes
 shrinkage cavities
C  Discontinuities
 Discontinuities, such as:

 cracks
 cold or hot tearing
 cold shuts.
 If the solidifying metal is
constrained from shrinking
freely, cracking and tearing
may occur.
C  Discontinuities
 Although several factors are

involved in tearing, coarse grain
size and the presence of low-
melting-point segregates along
the grain boundaries (intergranular)
increase the tendency for hot
tearing.
 Cold shut is an interface in a casting
that lacks complete fusion because
of the meeting of two streams of
liquid metal from different gates.
D  Defective surface
 Defective surface, such as:

 surface folds
 laps
 scars
 adhering sand layers
 oxide scale.
E  Incomplete casting
 Incomplete casting, such as:

 misruns (due to premature solidification)
 insufficient volume of the metal poured
 runout (due to loss of metal from the mold after
pouring).
 Incomplete castings also can result from the
molten metal being at too low a temperature or
from pouring the metal too slowly.
F  Incorrect dimensions or
shape
 Incorrect dimensions or shape, due to factors
such as:
 improper shrinkage allowance
 pattern-mounting error
 irregular contraction
 deformed pattern
 warped casting.
G  Inclusions
 Inclusions, which form during melting,

solidification, and molding; these are generally
nonmetallic.
 They are regarded as harmful because they act
as stress raisers and thus reduce the strength
of the casting. Inclusions may form during
melting when the molten metal reacts with the
environment (usually oxygen) or with the
crucible or mold material.
G  Inclusions
 Chemical reactions among components in the

molten metal itself may produce inclusions;
slags and other foreign material entrapped in
the molten metal also become inclusions,
although filtering can remove particles as small
as 30 m.
 Finally, spalling of the mold and core surfaces
can produce inclusions, thus indicating the
importance of the quality of molds and of their
maintenance.
Porositas
 Porositas dapat
terjadi akibat
terjadinya
penyusutan
(shrinkage),
gas yang
terjebak atau
ikut dalam
aliran logam
cair, atau
kedua-duanya.
Gas Solubility (1)
 Gas lebih mudah
larut dalam logam
cair dibandingkan
pada logam padat
(solid metal).
 Gas dapat terjadi
akibat reaksi antara
logam cair dan
material cetakan.
Gas Solubility (2)
 Gas yang terbawa atau terjebak akan
mengakibatkan timbulnya rongga atau
mengakibatkan microporosity.
Jelaskan bagaimana menghindari porositas

atau microporsitas yang diakibatkan oleh gas.
Gas Solubility (2)
Case : Piston
Aluminum piston for an internal Simulation of mold filling and solidification. (a)
combustion engine: (a) as-cast and (b) 3.7 seconds after start of pour. Note that the
after machining. mushy zone has been established before the
mold is filled completely. (b) Using a vent in the
mold for removal of entrapped air, 5 seconds
after pour.
MS 2260
MANUFACTURING PROCESSES I
Metal Casting
Process and
Equipment
Facilitator:
Dr. Ir. Tri Prakosa, M. Eng.
Mechanical and
Casting Methods
Sand Casting Investment Casting Die Casting

 High Temperature Alloy  High Temperature Alloy  High Temperature Alloy
 Complex Geometry  Complex Geometry  Moderate Geometry
 Rough Surface Finish  Moderately Smooth  Smooth Surface
Surface Finish
78
Summary of Casting Processes
Typical Cast Parts
(c)
(a)
(b) (d)
Figure 11.1 (a) Typical gray-iron castings used in automobiles, including the transmission
valve body (left) and the hub rotor with disk-brake cylinder (front). Source: Courtesy of
Central Foundry Division of General Motors Corporation. (b) A cast transmission housing.
(c) The Polaroid PDC-2000 digital camera with a AZ191D die-cast high-purity magnesium
case. (d) A two-piece Polaroid camera case made by the hot-chamber die-casting process.
Source: Courtesy of Polaroid Corporation and Chicago White Metal Casting, Inc.
Characteristics of Casting
Production Steps in Sand-Casting
Figure 11.2 Outline of production steps in a typical sand-casting operation.
Sand Mold
Figure 11.3 Schematic illustration of a sand mold, showing various features.
Pattern Plate
Figure 11.4 A typical metal match-plate pattern used in sand casting.
Design for Ease of
Removal from Mold
Figure 11.5 Taper on patterns for ease of removal from the sand mold
Sand Cores
Figure 11.6 Examples of sand cores showing core prints and chaplets to support cores.
Vertical Flaskless Molding
(c)
Figure 11.7 Vertical flaskless molding. (a) Sand is squeezed between two halves of the
pattern. (b) Assembled molds pass along an assembly line for pouring. (c) A photograph of a
vertical flaskless molding line. Source: Courtesy of American Foundry Society.
Sequence
of
Operations
for
Sand-
Casting
Figure 11.8 Schematic illustration of the sequence of operations for sand casting. (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 on next slide.
Sequence
of
Operations
for Sand-
Casting,
Con’t.
(g) The flask is rammed with sand and rthe plate and inserts are removed. (h) 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 securing the assembly with pins.
The flasks the are subjected to pressure to counteract 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). Source: Courtesy of Steel Founder’s Society of America
Shell-Molding Process
Figure 11.9 The shell-molding process, also called dump-box technique.

Shell Mold Casting
http://www.custompartnet.com/wu/shell-mold-casting
Shell Mold Casting
 Kelebihan dibanding sand casting:

 Toleransi dimensi lebih sempit,
 Permukaan produk lebih halus
 Lebih Murah
 Contoh Produk:
 Gear housing
 Cylinder head
Precision Casting
 Jenis-jenis precision casting:
 Plaster-mold casting
 Ceramic-mold casting
 Investment casting
 Contoh produk:
 Komponen kunci
 Roda gigi
 Katup
 Fitting
 Tooling
 Perhiasan
Plaster-mold Casting
 Bahan mold: plaster of paris (gypsum atau

kalsium sulfat), ditambah: talc dan tepung silika
 Pattern (pola mold) dibuat dari: aluminium
paduan, plastik thermosetting, kuningan atau
seng paduan.
 Bahan benda kerja: Aluminium, Magnesium,
Seng, dan paduan berbasis tembaga
Sequence of Operations
in Making a Ceramic Mold
Figure 11.10 Sequence of operations in making a

ceramic mold. Source: Metals Handbook, Vol. 5, 8th ed.
Expendable Pattern Casting
(Evaporative-pattern casting/loss foam casting)
Schematic illustration of the expendable pattern casting process, also known as

lost foam or evaporative casting.
Expandable-Pattern Casting Process
Figure 11.11 Schematic illustration of the expandable-pattern casting process, also

known as lost-foam or evaporative casting.
Expandable-Pattern Casting Process
 Contoh produk:
 cylinder heads
 engine blocks
 crank shafts
 brake components
 Manifolds
 machine bases
 Bahan pola: polystyrene

Evaporative Pattern Casting
of an Engine Block
(a) (b)
Figure 11.12 (a) Metal is poured into mold for lost-foam casting of a 60-hp. 3-cylinder
marine engine; (b) finished engine block. Source: Courtesy of Mercury Marine.
Investment Casting Process
Figure 11.13 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: Courtesy of Steel Founder’s Society of America.
Integrally Cast Rotor for a Gas
Turbine
Figure 11.14 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: Courtesy of
Howmet Corporation.
Comparison of Investment-Cast and
Conventionally Cast Rotors
Figure 11.15 Cross-section and microstructure of two rotors: (top) investment-cast;

(bottom) conventionally cast. Source: Advanced Materials and Processes, October 1990,
P. 25. ASM International.
Composite Molds
(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.
Vacuum-Casting
Figure 11.16 Schematic illustration of the vacuum-castin 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.
Vacuum-Casting (Counter-gravity
low pressure process
 For thin-walled complex shape with uniform
properties
 Example: gas turbine components from
superalloys, with 0.5mm wall thickness
 Fine sand and urethane is molded over metal
dies and cured with amine vapor.
 The mold is then immersed partially into molten
metal in induction furnace
 The vacuum is about 2/3 of atmospheric
pressure.
Hot-Chamber Die-Casting
Figure 11.17 Schematic illustration of the hot-chamber die-casting process.
Cold-Chamber Die-Casting
Figure 11.18 Schematic illustration of the cold-chamber 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 dies closed under pressure.
Properties and Applications of Die-
Casting Alloys
Types of Cavities in Die-Casting Die
Figure 11.19 Various types of cavities in a die-casting die.

Source: Courtesy of American Die Casting Institute.
Centrifugal-Casting Process
Figure 11.20 (a) Schematic illustration of the centrifugal-casting process. Pipes,

cylinder liners, and similarly shaped parts can be cast with this process. (b) Side
view of the machine.
Centrifugal Casting
horizontal sand-lined mold casting

vertical
Semicentrifugal Casting and
Casting by Centrifuging
Figure 11.21 (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.
Squeeze-Casting
Figure 11.22 Sequence of operations in the squeeze-casting process.

This process combines the advantages of casting and forging.
Methods of Casting Turbine Blades
(c)
Figure 11.23 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.
Crystal Growing
Figure 11.24 Two methods of crystal growing: (a)

crystal pulling (Czochralski process) and (b) the
floating-zone method. Crystal growing is important
especially in the semiconductor industry. (c) A single-
crystal ingot produced by the Czochralski process.
(c)
Source: Courtesy of Intel Corp.
Melt-Spinning
(b)
Figure 11.25 (a) Schematic illustration of melt-spinning to produce thin strips of

amorphous metal. (b) Photograph of nickel-alloy production through melt-spinning.
Source: Siemens AG
Types of Melting Furnaces
Figure 11.26 Two types of melting furnaces used in foundries:

(a) crucible, and (b) cupola.

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MS 2260 PROSES

Metal Casting Processes Foundries

Expendable mold Permanent mold Single crystal growing

Pada dasarnya proses casting (pengecoran) melibatkan :

1. Penuangan logam cair (pouring molten metal) ke dalam cetakan (mold)

Hal-hal yang perlu diperhatikan dalam proses pengecoran :

1. Aliran logam cair ke dalam rongga cetak (mold cavity)

Proses solidifikasi logam dipengaruhi oleh :

Faktor lain yang perlu diperhatikan :

Source: After G. W. Form, J. F.

Butir kristal tumbuh

Schematic illustration of three

 Because of the chilling

 As freezing proceeds, the

Characteristic of grain structure in a casting of a pure metal, showing randomly

 On further growth of spine,

Characteristic of grain structure in a casting of a pure metal, showing randomly

 The dendritic grains are

Characteristic of grain structure in a casting of a pure metal, showing randomly

(a) Phase diagram for a copper-nickel alloy system and

(a) Phase diagram for a copper-nickel alloy system and

(a) Phase diagram for a copper-nickel alloy system and

Characteristic of grain structure in an alloy casting, showing segregation of alloying

Characteristic of grain structure in an alloy casting, showing segregation of alloying

Columnar Dendritic Equiaxed Dendritic Equiaxed Non-Dendritic

Single Phase Two Phases

 Struktur yang terbentuk dan ukuran butir yang dihasilkan akan

Keberhasilan proses casting bergantung pada

base to the metal surface

  Castability : kemudahan suatu logam untuk dicor dengan mengahasilkan

 Contoh kasus : Pada pengecoran dengan ketebalan (dinding) produk

(bergantung pada : material coran, material cetakan dan parameter

 The effects of mold geometry and elapsed time on skin

 As illustrated, the unsolidified molten metal has been

 Note that (as expected) the skin thickness increases

 The latter condition is caused by slower cooling at

 Selama tahap awal pembekuan, lapisan tipis

 C merupakan konstanta yang mewakili :

 Mana yang lebih cepat menjadi padat dan dingin :

 Logam akan menyusut (shrinkage) selama

 Penyusutan terjadi akibat dari beberapa hal

 When liquid bismuth freezes, it expands

 Gray cast iron expands during solidification

 Menurut The International Committee of

Compiled By Agung Wibowo

 Metallic projections, consisting of: fins, flash, or

 Cavities, consisting of:

 Discontinuities, such as:

 Although several factors are

 Defective surface, such as:

 Incomplete casting, such as:

 Inclusions, which form during melting,

 Chemical reactions among components in the

Jelaskan bagaimana menghindari porositas

Sand Casting Investment Casting Die Casting

Figure 11.2 Outline of production steps in a typical sand-casting operation.

Figure 11.3 Schematic illustration of a sand mold, showing various features.

Figure 11.4 A typical metal match-plate pattern used in sand casting.

Figure 11.9 The shell-molding process, also called dump-box technique.

 Kelebihan dibanding sand casting:

 Bahan mold: plaster of paris (gypsum atau

Figure 11.10 Sequence of operations in making a

Schematic illustration of the expendable pattern casting process, also known as