CHAPTER 7 : CASTING PROCESS

CHAPTER 7: CASTING PROCESS

JF302 MATERIAL TECHNOLOGY 1

CONTENTS
1 2

Sand Casting

Lost Wax / Investment Casting Pressure Die Casting

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JF302 MATERIAL TECHNOLOGY 1

CASTING PROCESS
a method of producing a device or component a production process in which the materials needed, heated until molten and then poured into molds and allowed to solidify by cooling its own before being released for the machine to be cleaned or re can be categorized according to how filling molten metal into a mold and the mold material types used

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can produce complex components or complicated very small-sized goods until sized items can be produced economically

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BASIC ASPECTS CASTING PROCESS

1. MOLD CAVITY (CAVITY) -Space filled with molten metal mold must be able to withstand the pressure or weight of the molten metal is filled into it 2. SMELTING PROCESS - Must be able to produce molten material at the desired temperature 3. POURING TECHNIQUE -should use appropriate techniques space, cavity or passage to remove air and gas during casting shall be provided

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BASIC ASPECTS CASTING PROCESS

4. SOLIDIFICATION PROCESS -Consideration in relation to the contraction and cooling rates should be noted when designing the mold -designs that do not fit the mold caused a range of defects 5. REMOVING THE CAST METAL -Can be removed easily, especially when using the permanent mold 6. CLEANING, INSPECTION AND TESTING -To ensure it is of high quality or meet the specifications

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SAND CASTING

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JF302 MATERIAL TECHNOLOGY 1

SAND CASTING
The most popular casting process since time immemorial to the present a mold produced by compacting molding sands This mold is divided into two or more parts called "COPE" and "DRAG" a feed system that involves the construction of a feed channel (runner), gate (gate) and risers (riser) was built in the mold casting hollow (hollow castings) can be made by placing a core (core) in the mold

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suitable for producing cast various forms for almost all metals in any size with a low cost mold defects that may occur: Inclusion sand - Less messy mold grafting Cool cover - Casting at a temperature that is too low hot tearing - Inappropriate mold design porosity gas - The result of steam when there is moisture, low permeability mold and chemical reactions.

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SAND MOLDING
- Sand must be able to meet four basic requirements: Refractory nature To maintain shape when compacted in a mold Permeability Realibility -Most of the casting operation using silica sand (SiO2) and red sand -It is unable to resist high temperatures, has a range of sizes and a large range of grain shape

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- It also can be used repeatedly in a long time but do not have the feature to maintain good form - To obtain the required quality, clay is mixed up to 30% of the total weight of the mixture - Total mixed clay is different depending on the type and use of sand molds

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EQUIPMENT SAND CASTING

JF302 MATERIAL TECHNOLOGY 1

1. SAND mold - consisting of 85% silica sand, clay 8% and 7% water. 2. Mold box, a container used for making molds in it. Box mold comprising mold box above (Cope) and the mold box (Drag). It is made of wood or metal. 3. PATTERN - is a model or replica products made according to the original product in the form of castings. Made of wood, metal, plastic, wax and plaster. 4. CORE - to produce a mold cavity mold on the inside of casting products. Made of plaster, metal or ceramic. 5. BELLOWS - used to produce wind to produce grains of sand are on the ronggan mold or mold.

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6. BAR roller - used to smooth sand in the top or bottom of the mold box. Made of steel. 7. Spatula - for mold finishing work such as repairing a damaged mold, groove metal flow, make additions or penguarangan on the mold. 8. Casting spoon - used to repair minor damage to the mold cavity and groove metal flow. 9. Ram - used to compact the sand when making molds. Made of wood or metal. 10.WIRE vents - ventilation is used to produce pores in order to produce heat and gas contained with in the mold.

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11.DUST BAGS - filled with the powder to be sprinkled separation between the surface of the mold box up or down. 12.SPRUE - is used to form the inlet and outlet of the molten metal. 13.RISERS SCREW PATTERN - used to draw out the pattern from the sand. 14.DIPPER PROP - to remove the prop or impurities that float on the surface of the molten metal. 15.TOOL PENYAHGAS - to remove gases trapped in the molten metal.

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JF302 MATERIAL TECHNOLOGY 1

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STEP PROCESSING

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LOST WAX / INVESTMENT CASTING

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CANDLE CASTING LOST / INVESTMENT

Have unique characteristics and can produce complex components Can produce components with very small tolerances Using this type of aggregate and binder molding the same Has two variants, namely by using the shell mold and techniques

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STEPS PROCESSING
STEP 1 Patterns generated using paraffin wax-like, beeswax, and resin acrawax Wax pattern is dipped into the concentrated heat-resistant coating material to produce a smooth surface on the inside of the mold wall

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STEP 2 Pattern wax coated heat-resistant material is placed into a container of metal mold Melting material (material hardener and silica sand) poured into a mold and allowed to harden former in overall container mold for forming mold

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STEP 3 Wax mold is heated in a furnace at a temperature range of 100 C to 200 C Candlestick patterns are melting and flowing out to produce a mold cavity.

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STEP 4 Mold is removed from the furnace and reversed Molten metal is poured into the mold cavity When the molten metal has solidified, casting products may be released.

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JF302 MATERIAL TECHNOLOGY 1

CHAPTER 7: CASTING PROCESS

JF302 MATERIAL TECHNOLOGY 1

STEPS PROCESSING

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PRESSURE DIE CASTING

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JF302 MATERIAL TECHNOLOGY 1

PRESSURE DIE-CASTING
for materials that have a low melting temperature carried out by means of injection of a liquid metal into metal molds under pressure action high pressure 0.7MPa - 700MPa used to force molten metal into the mold cavity higher cooling rate can produce a uniform crystal structure with fine grain

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properties such as strength and yield point is better mold made of special steel and are known as die suitable to produce large-scale can produce complex-shaped and have a smooth surface finish Examples such as automotive components, toys, jewelry and household goods

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STEPS PROCESSING
STEP 1 Molten metal is inserted into the chamber

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STEP 2 Piston pushed in molten metal into the die cavity

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STEP 3 Core released and die manufacturers moving back

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STEP 4 Pin pusher will push out of the die casting products

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STEPS PROCESSING

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JF302 MATERIAL TECHNOLOGY 1

STEPS PROCESSING

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COMPARATIVE CASTING METHODS

Sand casting Any Pressure Die Casting Based alloy Cu, Zn, Al Very Good Wax Casting Any

Alloy / metal can be poured / processed Comparative mechanical properties surface finish Possibility to form complex shapes

Medium

Good

Medium Good

Very Good Very Good

Very Good Very Good