Process occur in casting

1. Patternmaking

-pattern is areplica of the exterior of the casting

-typically made of wood,plastics,metal and plaster

2. Coremaking

-if casting is hollow,an aditional piece of sand or metal(core) shapes the internal form to make it
hollow.

3. Molding

-is a multistep process that will form a mold around the pattern using molding sand.

4. Melting and pouring

-after liquid metal is melted,it is poured into the mold and left to solidify.

-once solidified,the shakeout process begin: the molds undergo vibration to remove sand from the
casting

5. Cleaning

-this is final step,the cast metal object is removed from mold and then fettled. During the fettling,the
object is cleaned of any molding material,and rough edges are removed.

Types of casting

1. Sand casting

-typically relies on silica-based materials, such as synthetic or naturally-bonded sand.

-generally consists of finely ground, spherical grains that can be tightly packed together into a smooth molding surface.

-designed to reduce the potential for tearing, cracking, or other flaws by allowing a moderate degree of flexibility and shrinkage
during the cooling phase of the process.

Advantages

-Least Expensive in small quantities (less than 100)

Ferrous and non - ferrous metals may be cast

Possible to cast very large parts.

• Least expensive tooling

Disadvantages

Dimensional accuracy inferior to other processes, requires larger tolerances

Castings usually exceed calculated weight

Surface finish of ferrous castings usually exceeds 125 RMS

2. Investment casting

-uses a disposable wax pattern for each cast part. The wax is either injected directly into the mold or pre-coated
with a liquid refractory material before injection.

-Molten forming material is then poured into the mold and allowed to harden and set into the shape of the wax
pattern.

- The component is then ejected, while the wax pattern is melted out of the casting and made available for reuse.

-often used to manufacture parts for the aerospace and automotive industries, as well the military.

Advantages

Close dimensional tolerance

Complex shape, fine detail, intricate core sections and thin walls are possible

Ferrous and non-ferrous metals may be cast

Disadvantages

Costs are higher than Sand, Permanent Mold or Plaster process Castings

3. Plaster casting

-similar to the sand casting process, using a mixture of gypsum, strengthening compound, and water in place of
the sand.

-The plaster pattern is typically coated with an anti-adhesive compound to prevent it from becoming stuck
against the mold, and the plaster is capable of filling in any gaps around the mold

-Once the plaster material has been used to cast a part, it usually cracks or forms defects, requiring it to be
replaced with fresh material.

Advantages

Closer dimensional tolerance than Sand Cast

• Intricate shapes and fine details including thinner "As Cast" walls are possible

• Large parts cost less to cast than by Investment process

Disadvantages

More costly than Sand or Permanent Mold-Casting

Limited number of sources

4. Die casting
-isa method of molding materials under high pressure and usually involves non-ferrous metals and alloys, such
as zinc, tin, copper, and aluminum.

-The mold is coated with lubricant to help regulate the die’s temperature and to assist with component ejection.

-Molten metal is then injected into the die under high pressure, which remains continuous until the workpiece
solidifies. This pressurized insertion is rapid, preventing any segment of the material from hardening before
being cast.

-After the process is completed, the component is taken out of the die and any scrap material is removed.

Advantages

Good dimensional tolerances are possible

Excellent part-part dimensional consistency

Parts require a minimal post machining

Disadvantages

-Economical only in very large quantities due to high tool cost

Not recommended for hydrostatic pressure applications