Die Casting

Hot chamber die casting

Cold chamber die casting

Investment casting

Investment casting (lost wax casting)

(a) Wax pattern (injection molding)

(b) Multiple patterns assembled to wax sprue

(d) dry ceramic melt out the wax fire ceramic (burn wax)

(c) Shell built immerse into ceramic slurry immerse into fine sand (few layers)

(e) Pour molten metal (gravity) cool, solidify [Hollow casting: pouring excess metal before solidification

(f) Break ceramic shell (vibration or water blasting)

(g) Cut off parts (high-speed friction saw) finishing (polish)

Investment casting (lost wax casting)

Investment casting is also called lost wax casting, one of the oldest known metal-forming techniques. The process is generally used for small castings, but has been used to produce complete aircraft door frames, steel castings of up to 300 kg and aluminum castings of up to 30 kg.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Produce a master pattern Mould making Produce the wax patterns Assemble the wax patterns Investment Dewax Burnout & Preheating Pouring Removal

Defects in casting

Defects in casting
Shifts caused due to core misplacement or mismatching of top and bottom parts of casting usually at parting line

Warpage undesirable deformation that occurs in casting after solidification . The remedy is to provide sufficient ribs and equal cooling rates

Fin thin projection of metal not intended as a part of casting. The remedy is to use sufficient weight on top part of mould .

Defects in casting
Swell enlargement of mould cavity by metal pressure. To avoid swells sand should be rammed properly

Blow holes entrapped bubbles of gases with smooth walls. To prevent this the moisture content in the sand must be well adjusted.

Drop upper surface of the mould cracks and pieces of sand fall into the molten metal which is caused due to insufficient reinforcement of sand, insufficient fluxing of metal. Dirt caused by crushing of mould due to improper handling, sand wash and presence of slag particles in the molten metal.

Defects in casting
Honeycombing or sponginess caused by dirt or scruf held mechanically in suspension in the molten metal.

Metal penetration and rough surface caused due to metal penetration between sand grains occurs due to low strength, large grain size, etc. Sand holes found on external surface or inside the casting, caused by loose sand washing into the mould cavity and fusing . Pin holes are small holes usually less than 2mm visible on the surface of casting .

Scabs sort of projection on the casting that occur when a portion of the face of the mould or core lifts .

Defects in casting
Shrinkage cavity Void or depression in the casting caused mainly by uncontrolled solidification of the metal .

Hot tears (Pulls) internal or external cracks having ragged edges occurring immediately after the metal has solidified .

Cold shut and misrun cold shut is an external defect formed due to imperfect fusion of two streams of metal in the mould cavity. Misrun is one which lacks completeness due to failure of the metal to fill.

Defects in casting
Poured short metal cavity is not completely filled at one pouring . Sufficient metal in the ladle at correct temperature will eliminate this defect.
Internal air pocket appears as small holes inside the casting which is caused by rapid pouring of metal in the mould.