Advanced Casting Processes

Dr.P.Sathiya Associate Professor Department of Production Engineering N.I.T. Trichy

Casting Process
It is a manufacturing process in which molten material is poured or injected into a mold (or cavity) and allowed to freeze so as to take form of the mold. The term casting is used to denote both the product and the process.

Attributes of a casting process

Most suited for intricate shapes and for parts with internal cavities, such as engine blocks, cylinder heads, pump housing, crankshaft, machine tool beds and frames, etc. cost of equipment and facilities required are relatively cheap Some shapes are possible only by casting

Why we go for Castings

Castings weighing from few grams to several tonnes can be produced Quantities (say) from even 1 to 100 can be produced. Several metals can only be cast Possible to make cast weld parts.

Sand Casting Steps

Casting Processes
Sand casting Investment casting Permanent mold casting Pressure die casting Squeeze casting Centrifugal casting Continuous casting

Sand Casting Steps

Sand Casting
Sand casting is the most common and versatile form of casting
Granular material (sand)is mixed with clay and water Packed around a pattern

Gravity flow is the most common method of inserting the liquid metal into the mold Metal is allowed to solidify and then the mold is removed

Schematic illustration of a sand mold

Sand Casting Advantages

Inexpensive mold Complex geometry All alloys Unlimited size Economical in low quantities Capital cost is low

Sand Casting - Disadvantages

Poor dimensional control Surface finish poor - Rough surfaces Vulnerable to contamination by loose sand Relatively labor intensive Dirty workplace Low productivity Automation is possible, but expensive
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The Making of Sand Molds

Hand ramming is the method of packing sand to produce a sand mold
Used when few castings are to be made Slow, labor intensive Nonuniform compaction

Molding machines
Reduce the labor and required skill Castings with good dimensional accuracy and consistency

Mold
Cope and drag Core Riser - Its function is to feed the rising to compensate for the shrinkage of molten material during cooling. Gating system - It consists of the pouring basin, sprue, runner and ingate. Its function is to fill the mold cavity in time so that the molten material does not solidify before filling the entire mold cavity.

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Cast Parts

Figure 12-17 A variety of sand cast aluminum parts. (Courtesy of Bodine Aluminum Inc., St. Louis, MO)

The permanent mold casting process consists of the following steps:

Mold preparation - First, the mold is pre-heated to around 300-500F (150260C) to allow better metal flow and reduce defects. Then, a ceramic coating is applied to the mold cavity surfaces to facilitate part removal and increase the mold lifetime. Mold assembly - The mold consists of at least two parts - the two mold halves and any cores used to form complex features. Such cores are typically made from iron or steel, but expendable sand cores are sometimes used. In this step, the cores are inserted and the mold halves are clamped together. Pouring - The molten metal is poured at a slow rate from a ladle into the mold through a sprue at the top of the mold. The metal flows through a runner system and enters the mold cavity. Cooling - The molten metal is allowed to cool and solidify in the mold. Mold opening - After the metal has solidified, the two mold halves are opened and the casting is removed. Trimming - During cooling, the metal in the runner system and sprue solidify attached to the casting. This excess material is now cut away.

Steps in permanent mold casting: (1) mold is preheated and coated

Steps in permanent mold casting: (2) cores (if used) are inserted and mold is closed

Steps in permanent mold casting: (3) molten metal is poured into the mold

Permanent Mold Casting

Permanent Mold Casting

Mold removed, not destroyed Uses gravity to fill mold Metal flow is slow Mold is steel - has comparatively good thermal conductivity Machines smaller

Permanent Mold Casting

Metals
Aluminum, Zinc, Magnesium, Copper,and Brass Alloys

Tolerances
+/- .012 first inch (add .002 per inch) Wall section .125

Normal Minimum Section Thickness:

Aluminum:.100" for small areas, up to 3/16" or more for large areas. Copper Base: .060" Ferrous: 3/16" for small areas, 1/4" normal.

Permanent Mold Casting

Pouring Process

Figure 13-19 Automatic pouring of molds on a conveyor line. (Courtesy of Roberts Sinto Corporation, Lansing, MI.)

Applications
Typical parts:
Gears Gear Housings Splines Fittings Ornamental Work Hardware Items

Advantages
Generally the same as all other multiple use moldsand mold life is about 25,000 + cycles

Disadvantages
Some limitations in complexity of mold and fine section detail may be limited

Continuous Casting
A water cooled mold is used to make a long casting of constant cross section Liquid metal is poured into the mold against a starter block As the metal solidifies it is removed exposing more liquid to the mold face

Continous Casting

Continous Casting

Continous Casting

Continous Casting

Investment Casting
IN INVESTMENT CASTING, a ceramic slurry is applied around a disposable pattern, usually wax and allowed to harden to form a disposable casting mold. The term disposable means that the pattern is destroyed during its removal from the mold and that the mold is destroyed to recover the casting.

Investment Casting- contd.

Also called lost-wax process

First used 4000 3000 BC

The pattern is made of wax or of a plastic by molding or rapid prototyping techniques

Term investment derives from the fact that the pattern is invested with the refractory material
Need careful handling because they are not strong enough to withstand the forces involved in mold making Wax can be recovered and reused

Investment cast parts

Aircraft engines, air frames, fuel systems Aerospace, missiles, ground support systems Agricultural equipment Automotive Baling and strapping equipment Bicycles and motorcycles Cameras Computers and data processing Communications Construction equipment Dentistry and dental tools Electrical equipment

Typical parts produced by investment casting.

(a)Single-crystal turbine blades (b) 17-4PH stainless steel fan exit case (c) Aircraft fuel sensor strut cast in 17-4PH SS

Biomedical applications for investment castings. (a) Whiteside hip-femoral prosthesis. (b) Whiteside II-C knee-tibial base. (c) London elbow-humeral prosthesis.

Miscellaneous applications for investment castings. (a) Nosepiece for nailgun cast (b) Ni-Resist Type II cast iron inducer for deep well oil drilling. (c) Small 17-4PH turbine vanes

Investment Casting Adv/Disadv.

Advantages
Good dimensional accuracy Rapid production rates possible Complex shapes Very high temp materials Titanium, Ni base , Co base alloys

Disadvantages
Long production cycle
leads to high cost per part

Mold is not reusable Cost of the refractory materials

Investment Casting
Sequential steps for investment casting
Produce a master pattern Produce a master die Produce wax patterns Assemble the wax patterns onto a common wax sprue Coat the tree with a thin layer of investment material Form additional investment around the coated cluster Allow the investment to harden Remove the wax pattern from the mold by melting or dissolving Heat the mold Pour the molten metal Remove the solidified casting from the mold

Investment Casting

Schematic illustration of investment casting

1. WAX INJECTION : Wax replicas of the desired castings are produced by injection molding. These replicas are called patterns.

2. ASSEMBLY : The patterns are attached to a central wax stick, called a sprue, to form a casting cluster or assembly.

3. SHELL BUILDING : The shell is built by immersing the assembly in a liquid ceramic slurry and then into a bed of extremely fine sand. Up to eight layers may be applied in this manner. 4. DEWAX : Once the ceramic is dry, the wax is melted out, creating a negative impression of the assembly within the shell.

5. CONVENTIONAL CASTING In the conventional process, the shell is filled with molten metal by gravity pouring. As the metal cools, the parts and gates, sprue and pouring cup become one solid casting.
6. KNOCKOUT When the metal has cooled and solidified, the ceramic shell is broken off by vibration or water blasting.

7. CUT OFF The parts are cut away from the central sprue using a high speed friction saw. 8. FINISHED CASTINGS After minor finishing operations, the metal castings-identical to the original wax patterns--are ready for shipment to the customer.

Die Casting
Liquid metal injected into reusable steel mold, or die, very quickly with high pressures Reusable steel tooling and injection of liquid metal with high pressures differentiates die casting from other metal casting processes

Sequence of operations in die casting of a part in the cold-chamber process.

Low Pressure Die Casting

Key Factors: -material to be cast: Steel -Pressure : added by inert gases

What if the mould is placed below the ladle bottom?

Cavity shaped reversibly like part cast

Mould

Sequence of steps in die casting of a part in the hot-chamber process.

The Low pressure-casting process uses graphite molds for the production of steel railroad wheels.

Low Pressure Die Casting

Key Factors: -material to be cast: Steel -Pressure : added by inert gases

What if the mould is placed below the ladle bottom?

Cavity shaped reversibly like part cast

Mould

Centrifugal Casting
Molten metal is poured and allowed to solidify in a revolving mold . Centrifugal force is developed due to rotation of the mold The metal solidifies from the outer rim of the casting . Best suited for hollow sections or parts with symmetry.

Advantages of CF casting
Solidification under Centrifugal force Directional solidification Free from gas and porosity Casting with good mechanical properties Inclusions collected at the inner surface

Applications
Cast iron pipes ( spun pipes) Cylinder liners Piston rings Gun barrels Brake drums Bushings Bimetallic Tubes

Centrifugal Casting
Utilizes the inertial forces caused by rotation to distribute the molten metal in to the mold cavities First used in the 1800;s Three types of centrifugal casting True centrifugal casting Semi centrifugal casting Centrifuging

Schematic illustration of the centrifugal casting process. Pipes, cylinder liners, and similarly shaped parts can be cast with this process.

(a) Schematic illustration of the semicentrifugal casting 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 forces.

Squeeze casting
Squeeze casting, also known as liquid-metal forging, is a process by which molten metal solidifies under pressure within closed dies positioned between the plates of a hydraulic press. The applied pressure and the instant contact of the molten metal with the die surface produce a rapid heat transfer condition that yields a porefree fine-grain casting with mechanical properties approaching those of a wrought product. The squeeze casting process is easily automated to produce nearnet to net shape high-quality components. Aluminum, magnesium, and copper alloy components are readily manufactured using this process. Several ferrous components with relatively simple geometry--for example, nickel hard-crusher wheel inserts--have also been manufactured by the squeeze casting process.

Squeeze Casting

Schematic illustrating squeeze casting process operations. (a) Melt charge, preheat, and lubricate

Squeeze Casting
(c) Close die and apply pressure

(a) Melt Metal

(d) Eject squeeze casting and charge melt stock and repeat cycle

(b) Pour molten metal into die

Sequence of operations in the squeeze-casting process. This process combines the advantages of casting and forging.

Different Casting Processes

Process Sand Shell mold Expendable pattern Plaster mold Ceramic mold Investment Permanent mold Die Centrifugal Advantages many metals, sizes, shapes, cheap better accuracy, finish, higher production rate Wide range of metals, sizes, shapes complex shapes, good surface finish complex shapes, high accuracy, good finish complex shapes, excellent finish good finish, low porosity, high production rate Excellent dimensional accuracy, high production rate Large cylindrical parts, good quality Disadvantages poor finish & tolerance limited part size patterns have low strength non-ferrous metals, low production rate small sizes small parts, expensive Costly mold, simpler shapes only costly dies, small parts, non-ferrous metals Expensive, few shapes Examples engine blocks, cylinder heads connecting rods, gear housings cylinder heads, brake components prototypes of mechanical parts impellers, injection mold tooling jewellery gears, gear housings gears, camera bodies, car wheels pipes, boilers, flywheels

Misrun
A casting that has solidified before completely filling mold cavity

Cold Shut
Two portions of metal flow together but there is a lack of fusion due to premature freezing

Cold Shot
Metal splatters during pouring and solid globules form and become entrapped in casting

Shrinkage Cavity
Depression in surface or internal void caused by solidification shrinkage that restricts amount of molten metal available in last region to freeze

Sand Blow
Balloon-shaped gas cavity caused by release of mold gases during pouring

Pin Holes
Formation of many small gas cavities at or slightly below surface of casting

Penetration
When fluidity of liquid metal is high, it may penetrate into sand mold or sand core, causing casting surface to consist of a mixture of sand grains and metal

Mold Shift
A step in cast product at parting line caused by sidewise relative displacement of cope and drag