TOPIC : FOUNDRY

1. SAND CASTING
2. LOST FOAM CASTING
3. PLASTER MOLD CASTING
LEARNING OUTCOMES :

Analyze different terms, features and functions use in sand casting process, lost form
casting process and mould making using Plaster of Paris.
Contribute innovative ideas for producing foundry product and automation solution
that meet market environment.

INTRODUCTION
1. Sand casting
Sand casting, also known as sand molded casting, is a metal casting process characterized
by using sand as the mold material. The term "sand casting" can also refer to an object
produced via the sand casting process. Sand castings are produced in specialized factories
called foundries. Over 70% of all metal castings are produced via sand casting process.Sand
casting is often utilized in industry (automotive, aerospace, etc.) to make parts that are
comprised of iron, bronze, brass and at times aluminum. The metal of choice is melted in a
furnace and poured into a mold cavity formed out of sand. Sand casting is used because it is
inexpensive and the process is relatively simple. However, flaws are common in sand cast
parts and these flaws can affect the properties of the cast materials. As a result, this exercise
can be used both to teach the sand casting process and also to demonstrate the effect
processing has on defect formation
2. Lost foam casting
Lost-foam casting (LFC) is a type of evaporative-pattern casting process that is similar to
investment casting except foam is used for the pattern instead of wax. This process takes
advantage of the low boiling point of foam to simplify the investment casting process by
removing the need to melt the wax out of the mold.This process eliminates the need for sand
binders and cores. The sand is unbonded and a foam pattern is used to form the shape of the
casting. The foam pattern is invested into the sand at the Fill & Compact process station
allowing the sand into all voids and supporting the foam patterns external form. The sand is
introduced into the flask containing the casting cluster and compacted to ensure all voids and
shapes are supported.

3. Plaster mold casting

Plaster mold casting is a metalworking casting process similar to sand casting except the
molding material is plaster of Paris instead of sand. Like sand casting, plaster mold casting is
an expendable mold process, however it can only be used with non-ferrous materials. It is
used for castings as small as 30 g (1 oz) to as large as 45 kg (99 lb). Generally, the form takes
less than a week to prepare. Production rates of 110 units/hr can be achieved with plaster
molds.The plaster is not pure plaster of Paris, but rather has additives to improve green
strength, dry strength, permeability, and castability. For instance, talc or magnesium
oxide are added to prevent cracking and reduce setting time; lime and cement limit expansion
during baking; glass fibers increase strength; sand can be used as a filler. [1] The ratio of
ingredients is 7080% gypsum and 2030% additives. The pattern is usually made from
metal, however rubber molds may be used for complex geometry; these molds are
called Rubber plaster molds. For example, if the casting includes reentrant angles or complex
angular surfaces then the rubber is flexible enough to be removed, unlike metal.

OBJECTIVE :

Understand the safety aspects of foundry work.

Understand the working principles of common foundry tools and devices.
Understand the principles, types and techniques of foundry work.
Know foundry materials, their composition, properties and application.

SAFETY PRECAUTIONS :
1) Wear safety shoes if heavy work is being done.
2) Wear clothing suited for the job, wear shoes with thick soles.
3) Dont wear rings, watches, braslets or other jewellery that could get could get caught
in moving machinery.
4) Dont wear neck ties or loose turn clothing of any kind.
5) Wear shirts or uppers with sleaves cut off or rolled above the elbows.
6) If material is rough and sharp then gloves must be work place or handle material.
7) Wear leather glove, apron and face shield during pour molten metal

FIGURE : Model for safety precaution

PROCEDURE :
Sand casting
1. Firstly,the green sand is putted into the sand muller machine. Then,some water is added
to moisture the green sand. The machine is switched on.
2. The selected pattern is placed properly to the flask (make sure that the flask has been
aligned using alignment pins and locks).
3. After that, parting powder is sprinkled at the drag side of the flask. The drag side is
sieved and filled with green sand. After filling, bench rammers is used to compact it. The
excess sand is striked with the strike off bar.
4. The flask is turned to cope side. The sprue and riser is placed at the appropriate
location. Step 3 is repeated.
5. Pouring basin and gate is made using leaf and square spoon.
6. Lastly, the sprue, riser and pattern is removed. Mold halves are mated and prepared for
metal pouring process.

 Lost foam casting

1. Make the Styrofoam patterns (product) using polystyrene.
2. The parts foam patterns are glue together along with the sprue (gating systems).
3. The pattern is placed in silica sand and make sure the sand is compact to the pattern.
4. The cast molten metal(aluminium) is poured into the pattern. Then, the foam will
evaporate, and escape through the normal routes gas evacuates through.

FIGURE : Process of pouring molten metal

5. After that, the part is leave for it to cool down and solidified.

FIGURE : Leaved to solidified

6. After it fully solidified, the sand is removed. Then, the product is been taken out from
the sand.

FIGURE : The product is taken out

7. The product is being observed to be recorded.

Note:
1. For high quality surface finish the polystyrene patterns and gating system may
becoated with ceramic slurry and hardened in a drying oven.
2. If a ceramic coating was used the metal product can be removed using
impact,vibration, or abrasive techniques as appropriate.

Plaster mold casting

1. Firstly, the pattern is created.

FIGURE : Pattern that being created

2. Then, mix the Plaster of Paris with water. The ratio of Plaster of Paris with the water is
1: 1.
3. Quickly, the mixture is poured into the container.
4. The pattern is leaved for hours to dehydrating.
5. After dehydrating, the pattern is move carefully to avoid from damage the mould
surface.

FIGURE : The pattern is being removed

Results :
Lost foam casting

FIGURE : Success product

FIGURE : Failure product

Plaster mold casting :

FIGURE : Success product

FIGURE : Failure product

TYPE OF DEFECT

Defect

Causes

Unfilled sections

Insufficient material

Low pouring temperature

Melt temperature is too high

Non-uniform cooling rate

Sand has low permeability

Hot tearing

Non-uniform cooling rate

Surface
projections

Erosion of sand mold interior

A crack in the sand mold

Mold halves shift

Porosity

Discussion :

Sand casting is to identify the casting defect that can be observed from the metal
product produced. We must list down the possible countermeasures that can be put into
practice to minimize the defects. We also must list down safety precaution that need to be
taken into consideration during pouring the molten metal into the mould. Must know all
the equipments and tools used in the sand casting process . Must know the functions and
uses in the related process. After finished write the full report of sand casting process that
our group conduct with additional suggestion in order to produce a better quality casting
product.
For expandable-pattern (lost foam) casting we must know and identify all the casting
defect that can occur to the product. Must list down the possible countermeasures that can
be put into practices to minimize the defects. We give our recommendation for the
bestgating system design for this process and justify the recommendation by referring to
some literatures. Same as after finish doing casting we write the full report of our activity.
Next is plaster mold casting . Plaster mold casting first is same like sand casting we
identify the defect then we list down the countermeasures and next we justification for the
best mixing ratio for plaster of paris (POP) and water we use ratio 1: 1 for (POP) and
water.

Conclusion :
From this experiment, we can conclude that many product have different process of
producing it. For the biggest product always easy to produce by using sand casting. Then,
product that hard to shape usually using casting method because it can gain the fix shape
of the product. So, we can use this casting process to contribute innovative ideas for
producing foundry product and automation solution that meet market environment.

Department of Manufacturing and Industrial Engineering

Faculty of Mechanical and Manufacturing Engineering
Universiti Tun Hussein Onn Malaysia 86400 Parit Raja,
Batu Pahat, Johor Darul Tazim
WORKSYOP REPORT

TOPIC 4 : FOUNDRY

GROUP MEMBER :

1.
2.
3.
4.

ABDUL AZIZ SHABUDIN BIN SIRAJUDDIN

MOHD SYUAIB BIN SAPEHI
MOHD FAZRIL BIN MOHD AHIR
MUHAMMAD HAFIZ BIN MOHD ZAIN

LECTURER NAME : REAZUL HAQ BIN ABDUL HAQ

MATRIC NO.

(AD150062)
(CD150060)
(CD150177)
(CD150184)

References:
https://en.wikipedia.org/wiki/Sand_casting#cite_ref-rao18_10-2
https://en.wikipedia.org/wiki/Lost-foam_casting
https://en.wikipedia.org/wiki/Plaster_mold_casting
http://www.custompartnet.com/wu/SandCasting#possible_defects
http://energy.gov/eere/amo/improvement-lost-foam-casting-process