Cast Iron, Cast Steel and

Powder Metallurgy
Properties of Materials
BTM2413

Casting Process
Casting a shape achieved by allowing
liquid to solidify in a mold
Casting process
Sand Casting

Casting Process
Die Casting

Casting Process
Permanent Mold Casting

Casting Process
Shell molding Casting

Casting Process
Centrifugal casting

Casting Mold
Sand mold
- Mold made by sand

Casting Mold
Metal mold
- Mold made by metal
Graphite
mold

Melting Techniques
a)Cupola

Melting Techniques
-Cast iron melting process in cupola
Burning the coke
Air is supply to the coke bed
Solid metal charged into the furnace through
charging door
The metal is alternated with layers of coke and drip
down through the coke bed
When the metal level is sufficiently high, tap hole is
opened to collect the molten metal

Melting Techniques
b) Electric Arc

Melting Techniques
c) Induction

Melting Techniques
d) open-hearth

Melting Techniques
e) reverberatory

Factors Of Casting Process

Factors to be Considered in evaluating/selecting a
casting process:
1) Tolerance
-) It is needed to compensate with shrinkage rate
(1% -5%)
-) Depend on nature of the metal being cast
(melting point) and nature of process.
-) Investment castings have the lowest tolerances
that apply to ferrous and non-ferrous
-) Sand casting has the largest tolerances

Factors Of Casting Process

2) Surface Finish
Process
Die casting

Surface Roughness (m)

0.5 2.5

Investment Casting

1.25 2.5

Shell Molding

6.25 17

Sand Casting

6.25 - 25

Factors Of Casting Process

3) Size Limitations
- Large die casting may weight up to 18 kg
- Investment casting seldom exceed 13kg, seldom
longer than 450 mm
- No size limit for sand casting
- Most cast-iron pipes are centrifugal casting
4) Materials
- Permanent mold and centrifugal casting suitable
for ferrous metal
- Shell molding, investment casting, sand casting,
centrifugal casting, and permanent mold can be
applied to all common metal

Factors Of Casting Process

3) Casting cost
- Depend on hardware used; sand casting :
hardware required is wooden pattern, other
process mostly metal mold and quite expensive
- Sand casting required long time to process
- Die casting is the fastest process
4) Availability
- Time to build the hardware
-sand casting is the simplest process

Powder Metallurgy
Powder Metallurgical Process
1) Blending of powders
-) Metal powders in the size range from 10 to 80
m, are blended to achieve the desired powder
mix and to add compaction lubricants
2) Filling of compaction die
-) The powder is fed into the open die
3) Compaction
-) The upper and lower compaction tools then
simultaneously compact the powder with
pressure.
-) Compaction is performed in hardened steel
tooling machine

Powder Metallurgy
Powder Metallurgical Process
4) Part ejection
- Upper compaction punch retracts and the lower
punch rises to eject the compacted shape
5) Sintering

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