Module-3 Metal Casting

MODULE : 3
METAL CASTING
MATHEW SAMUEL
LECTURER, SOE
CUSAT
CASTING
A manufacturing process that pours a liquid material
into a hollow mould until the material cools into a

solidified shape.
A material in a liquid or semisolid form is poured or
forced to flow into a die cavity and allowed to

solidify, thus taking the solid shape of the cavity.
The process can be applied on metals and plastics.
Typical examples of the product produced by casting
process Engine Block, Machine tool parts, etc.

2
MATHEW SAMUEL, LECTURER SOE CUSAT
7/31/15
CASTING PROCESS
In pattern making, a physical model of casting, i.e. a
pattern is used to make the mold.

Apatternis a replica of the object to be cast, used to
prepare the cavity into which molten material will be

poured during thecastingprocess.
The
mold is made by packing some readily formed

aggregated materials, like molding sand, around the
pattern.
After the pattern is withdrawn, its imprint leaves the mold
cavity , that is ultimately filled with metal to become the

casting.
3
VIDEO
CASTING
PROCESS
MATHEWOF
SAMUEL,
LECTURER
SOE CUSAT
7/31/15
Steps involved in casting process

Pattern making.
Mould making.
Core making.
Melting of metal and pouring.
Cooling and solidification
Cleaning of castings and inspection
4
7/31/15
PATTERN
7/31/15
PATTERN
Apatternis a replica of the object to be cast,
used to prepare the cavity into which molten

material
will
be
poured
during
thecastingprocess.
A Pattern prepares a mould cavity for the purpose of
making a casting.
Properly constructed patterns minimize overall cost of the
casting.
7/31/15
PROPERTIES OF PATTERN MATERIAL

It
should be easily shaped, worked,

machined and joined.
It should be resistant to wear and
corrosion.
It should be resistant to chemical action.
It should be dimensionally stable and must
remain
unaffected
by
variations
in
temperature and humidity.
It should be easily available and
economical.
7
7/31/15
PATTERN MATERIALS
1. WOOD
Easily available
Low weight
Low cost
It absorbs moisture and hence dimensions will
change
Lower life
Suitable for small quantity production and very
large size castings.
Limitations: Inherently non uniform in structure,
posses poor wear and abrasion resistance, cannot
withstand rough handling, absorbs and gives off
moisture.
8
7/31/15
PATTERN MATERIALS
2. METAL
Used for mass production
For maintaining closer dimensional tolerances on
casting.
More life when compared to wooden patterns
Few of the material used include CI, Al, Fe, Brass
etc. Al is widely used.
Have a smooth surface
Can withstand rough handling
Resistant to wear, abrasion, corrosion and swelling.
Limitations : expensive, not easily repaired, heavier
than wooden patterns
9
7/31/15
PATTERN MATERIALS
3.
PLASTIC
Low weight
Easier formability
Do not absorb moisture
Good corrosion resistance
Strong and dimensionally stable.
4. POLYSTYRENE
Used for prototype (single piece) castings
Also known as Disposable patterns.
10
7/31/15
TYPES OF PATTERNS
11
SINGLE PIECE/SOLID PATTERN:

Simple shape castings are produced by this
type of patterns.
It is the simplest form of pattern exactly
like the desired casting.
It is inexpensive.
One piece Pattern is made from one piece
and does not contain loose pieces or joints.
One piece Pattern is usually made of wood
or metal depending up on the casting to be
produced.
7/31/15
Stuffing box of a steam engine is an
SPLIT/PARTED PATTERN
Many patterns cannot be made in a single
piece because of the difficulties associated

with the moulding operations.
To eliminate this difficulty and for castings
of intricate shape or unusual shape, split
patterns are employed to form the mould.
These patterns are made in two parts.
So that one part will produce the lower

half of the mould and the other, the
upper half.
The line of separation of two parts is called
12
the Parting Line

Spindles, cylinders, steam valve bodies,7/31/15
LOOSE PIECE PATTERN

Certain patterns cannot be withdrawn once
they are embedded in the molding sand.

Such patterns are usually made with one or
loose pieces for facilitating their removal

from the moulding box and are known as
Loose Piece Patterns.
13
7/31/15
MATCH PLATE PATTERN

Split pattern having the cope and drag
portions mounted on opposite sides of a

plate.
Several patterns can be mounted on one
match plate if the size of the casting is
small.
Piston rings of IC engines are produced by
this method.
14
7/31/15
GATED PATTERN
A gated pattern is simply one or more loose
patterns having attached gates and

runners.
These patterns are used for producing
small castings in mass production system.
15
7/31/15
COPE AND DRAG PATTERNS

Split
pattern having the cope and drag

portions each mounted on separate match
plates
Used in production of large castings.

For higher rate of production, each half of the
pattern is mounted on a separate molding

machine, one operator working on the cope
part of the mould and the other on the drag
part of the mould
16
7/31/15
SWEEP PATTERNS
Sweep pattern is preferred for producing
large castings of circular sections and

symmetrical shapes.
Sweep Pattern consists of a wooden board
having a shape corresponding to the shape
of the desired casting and arranged to
rotate about a central axis.
When the board is rotated about the axis
mould cavity of the desired shape is
obtained in the mould.
17
7/31/15
SEGMENTAL PATTERN
The segmented pattern is similar to Sweep
Pattern , in the sense that both types

employ a part of a complete pattern for
getting the required shape of the pattern.
The segmented pattern is in the form a
segment and is used for producing circular

shapes.
18
7/31/15
SKELETON PATTERN
For large casting having simple geometrical
shapes(for example water pipes, turbine

casings etc.), Skeleton Pattern are used.
These are simple frames that outline the
shape of the part to be cast.
19
7/31/15
FOLLOW BOARD PATTERN

Follow Board is not a pattern but is a device
used for various purposes.

It is used for supporting a pattern which is
very thin and fragile which may break or
collapse under pressure when the sand
above is rammed.
20
7/31/15
PATTERN ALLOWANCES
The amount of something that is permitted, especially
within a set of regulations or for a specified purpose.

To compensate for any dimensional and structural
changes which will happen during the casting process,

allowances are usually made in the pattern
21
7/31/15
TYPES OF PATTERN ALLOWANCES

1. SHRINKAGE ALLOWANCE
2. MACHINING ALLOWANCE
3. DRAFT OR TAPER ALLOWANCE
4. DISTORTION ALLOWANCE
5. RAPPING OR SHAKE ALLOWANCE
22
7/31/15
SHRINKAGE ALLOWANCE
All most all cast metals shrink or contract
volumetrically on cooling.
Provided to compensate for shrinkage of
material
Pattern is made slightly bigger
Amount of allowance depends upon type
of material, its composition, pouring
temperature etc.
Different metals shrink at different rates
because shrinkage is the property of the
cast metal/alloy.
23
7/31/15
SHRINKAGE ALLOWANCES(contd.)
The metal shrinkage depends upon:
1.
The cast metal or alloy.
2.
Pouring temp. of the metal/alloy.
3.
Casted dimensions(size).
4.
Casting design aspects.
5.
Molding conditions(i.e., mould materials and

molding methods employed)
24
7/31/15
MACHINING ALLOWANCE
Provided to compensate for machining on
casting.
Pattern is made slightly bigger in size.
Amount of allowance depends upon size

and shape of casting, type of material,
machining process to be used, degree of
accuracy and surface finish required etc.
25
7/31/15
MA depends on..
i.
Nature of metals: Ferrous metals need more allowance than

Non Ferrous metals.
ii.
Size and shape of casting.
iii.
The type of machining operations to be employed for

cleaning the casting.(grinding, sand paper, other machines)
26
iv.
Degree of finish.
v.
Molding process employed.
7/31/15
DRAFT OR TAPER ALLOWANCE

Provided to facilitate easy withdrawal of the pattern.
Typically it ranges from 1 degree to 3 degree for wooden
patterns.
Draft allowance is given so that the pattern can be easily
removed from the molding material tightly packed around

it with out damaging the mould cavity.
27
7/31/15
TA depends on..
i.
Shape and size of pattern in the depth direction in contact with

the mould cavity.
28
ii.
Moulding methods.
iii.
Mould materials.
7/31/15
DISTORTION ALLOWANCE
Provided on patterns whose castings tend
to distort on cooling
29
7/31/15
MOLD
30
7/31/15
MOLD MATERIAL
A mold material is one, out of which mold is
made.
A mold material should be such that mold
cavity retains its shape till the metal has
solidified.
31
1. Permanent Molds made up of Steel or

Grey Cast Iron
2. Temporary refractory molds made up
of refractory sand and resins.
3. Molds may also be made up of wax,
MATHEWplaster
SAMUEL, LECTURER
SOE CUSAT
of paris,
carbon, ceramics etc.7/31/15
MOLD(contd.)
Refractory sands :They are
1. Silica sand
2. Zircon
3. Magnesite
4. Graphite etc
Refractory sand are the best molding sands.
They maintain their shape and characteristics even at
32
high temperatures.
They have good permeability.
They can be molded into intricate shapes.
7/31/15
MOLDING SAND
Ingredients of Molding Sand are :
1. Sand
2. Binders
3. Water
4. Additives
Sources of Molding Sand:
1. River Beds
2. Sea
3. Lakes
4. Desert
33
7/31/15
TYPES OF MOLDING SAND

1. Natural Sands
2. Synthetic Sands
3. Loam Sands
NATURAL SAND
Natural sand is directly used for molding and contains 5-20% of
clay as binding material.

It can maintain moisture content for a long time.
They are inexpensive.
It can be easily repaired. Used for casting cast iron and nonferrous metals.
34
7/31/15
SYNTHETIC SAND
Synthetic sand consists of silica sand with or without clay, binder or
moisture.
It is a formulated sand i.e. sand formed by adding different
ingredients.
These sands have better casting properties like permeability and
refractoriness and are suitable for casting ferrous and non-ferrous

materials.
These properties can be controlled by mixing different ingredients.
Synthetic sands are used for making heavy castings.
35
7/31/15
LOAM SAND
Loam sand contains many ingredients, like fine sand particles,
finely ground refractories, clay, graphite and fiber reinforcements.

In many cases, the clay content may be of the order of 50% or
more.
When mixed with water, the materials mix to a consistency
resembling mortar and become hard after drying.

Big molds for casting are made of brick framework lined with
loam sand and dried.
36
7/31/15
PROPERTIES OF MOLDING SAND

1. Flowability : It is the ability of the molding sand to
get compacted to uniform density.
2. Green Strength : It is the strength of the sand in
moist condition. A molding sand with adequate Green
Strength will retain its shape, will not distort.
3. Dry Strength : It is the strength of the sand in dry
condition.
4. Permeability : It is the ability of a molding sand to
allow the passage of mold gases through them. Mold
gases may be produced by the reaction of molten
metal with the moisture or binders.
5. Refractoriness : It is the ability of the sand to
withstand high temperature.
37
7/31/15
PROPERTIES OF MOLDING
SAND(contd.)
6. Adhesiveness : It is the ability of the sand to
stick on to the mold walls.
7. Collapsibility : It is the ability of the sand to
collapse after the casting solidifies.
8. Fineness : It is the ability of the sand to
produce smooth surfaced castings.
9. Coefficient of Expansion : A good molding
sand should have less coefficient of expansion.
10. Durability : It is the ability of the sand to be
used again and again.
38
7/31/15
PROPERTIES OF CORE
It must be strong to retain the shape while handling,
It must resist erosion by molten metal,
It must be permeable to gases,
It must have high refractoriness, and
It must have good surface finish to replicate it on to the
casting.
CORE: Acoreis a device used

incastingandmoldingprocesses to produce
internalcavities. The core is normally a disposableitem
that is destroyed to get it out of the piece.
39
7/31/15
GATING SYSTEM
It refers to the passageway through which
molten metal passes to enter mould cavity.
40
7/31/15
SPRUE
A sprue is the passage through which liquid material is
introduced into a mold.

During casting or molding, the material in the sprue will
solidify and need to be removed from the finished part.
41
7/31/15
POURING CUPS
Funnel shaped cup which forms the top
portion of the sprue.

It is used to direct the flow of molten metal
to the sprue.
RUNNER
Connects sprue with gates.
GATES
Gate is a channel which connects runner
42
with mold cavity.

Gates feeds molten metal to the mold
7/31/15
RISER
It provide many advantages as follows,
In the initial stages of pouring it allows the air, steam and
gases to go out of the mould.

On seeing the rising molten metal through it, it is ensured
that the mould cavity has been completely filled up.

It act as a reservoir to feed the molten metal to the casting
to compensate the shrinkage during solidification
43
7/31/15
Functions of a gating system

1. Fill the mold cavity before solidifying.
2. Introduce
the molten metal with less

speed and less turbulence so that mold
erosion and metal oxidation is prevented.
3. Regulate the rate at which the molten
metal entering the mold cavity.
4. Should consume less metal. ie., less metal
should be solidified in the gating system.
44
7/31/15
TYPES OF CORES
1.
2.
3.
4.
5.
6.
45
Horizontal Core
Vertical Core
Hanging Or Cover Core
Balanced Core
Drop or Stop Off Core
Kiss Core
7/31/15
HORIZONTAL CORE
Horizontal Core is placed horizontally in the
mold.
It is supported in core seats at both the
ends.
It may have any shape, circular or some
other section depending up on the shape of
the cavity required in the casting.
These are generally placed at the parting
line
46
7/31/15
VERTICAL CORE
A Vertical Core is placed vertically in the
mold.
A Vertical Core is supported in core seats at
both the ends.
It may have any shape, circular or some
other section depending up on the shape of
the cavity required in the casting.
A big portion on the vertical core remains in
the drag.
Vertical Cores are generally placed at the
parting line.
47
7/31/15
HANGING OR COVER CORE

A hanging core is supported from above &
it hangs vertically in the mold cavity.

A hanging core has no support from
bottom.
48
7/31/15
BALANCED CORE
A Balanced Core is supported in one end
only.
A Balanced Core requires a long core seat
so that core does not sag or fall into the
mold.
49
7/31/15
DROP OR STOP OFF CORE

A Drop Core is used when a hole or cavity is
required in a casting not in the parting

surface but above or below the parting
surface.
Tapering is given to the core for easy
location.
50
7/31/15
RAM UP CORE
Ram up core is placed in the sand along
with the pattern before ramming the sand.

It cannot be placed after the mold has been
rammed.
Ram up core is placed in the mold so as to
obtain cavities which are inaccessible after
the mold is prepared.
51
7/31/15
KISS CORE
A kiss core is not supported by core seats.
A kiss core is placed between cope and
drag due to the pressure exerted by cope

on the drag.
A
number
of
kiss
core
can
be
simultaneously positioned in order to
obtain a number of holes in casting.
52
7/31/15
TYPES OF MOLDING
PROCESS
53
7/31/15
GREEN SAND MOLDING
Green sand is a sand which contains water.

In a Green Sand Mold the molten metal is
poured when is in the green state i.e., in

the un dried state.
Intricate shapes can be produced in Green
Sand Mold.
These are suitable for producing small and
medium sized castings.
It is specially employed for producing nonferrous castings.
54
7/31/15
ADVANTAGES
No mold baking or drying is required.
There is less mold distortion than in dry
sand molding.
Time and cost associated with mold baking
or drying is eliminated.
Green sand molds having smaller depths
permit the escape of mold gases without
any difficulty.
Green sand molding provides good
dimensional accuracy.
55
7/31/15
DISADVANTAGES
Lower strengths.
They are less permeable.
There are more chances of defects (like
blow holes etc.) occurring in castings made

by green sand molding.
Green sand molding does not impart good
surface finish on castings.
56
7/31/15
DRY SAND MOLDING

Dry molding sand differs from the green
molding sand in the sense that it contains

binders (like clay, bentonite, molasses etc.)
which harden when the mold is heated or
dried.
Dry sand molds are actually made with
molding sand in green condition and then

the entire mold is dried in ovens.
57
7/31/15
ADVANTAGES
Possess high strength.
More permeable
as compared to green
sand molds.
Castings produced from dry sand molds
possess clean and smooth surfaces.
Less defects.
Better overall dimensional accuracy to the
molds and castings as compared to green
sand molding.
Preferred for large sized castings.
58
7/31/15
DISADVANTAGES
Dry sand molding involves more labour and
consumes more time in completing the

mold.
Mold baking is an extra work as compared
to that required in green sand molding.
Dry sand molding is more expensive as
compared to green sand molding.
59
7/31/15
SKIN DRIED MOLDING

The mold is made with the molding sand in
green condition.
Then the skin of the mold cavity is dried up
with help of gas torches or radiant heating
lamps.
Skin Dried mold is dried up to a depth
varying from 6mm to 25 mm.
A Skin Dried mold possess strength and
other characteristics in between green and
dried sand molds.
60
7/31/15
AIR DRIED MOLDING

The mold is made with the molding sand in
green condition and then it is kept open to

the atmospheric air for a certain period of
time.
During that period some of the moisture
from the mold surface gets evaporated and

consequently the mold skin dries thereby
increasing the strength and hardness of the
mold surface.
61
7/31/15
CEMENT BONDED SAND MOLDING

Cement
bonded sand mold material

consists of 85.5% clean silica sand,
10%potland cement and 4.5% water.
Mold Sand does not require much ramming.
Cement-Sand Mold develop strength and
hardness owing to the setting action of the
Portland cement.
The mold is permitted to continue setting
for a period of about 72 hours.
Accurate and smooth surfaced casting.
62
7/31/15
METAL MOLDS
Metal molds are generally made of Grey
Cast Iron or steel.

Metal Molds are preferred for casting nonferrous metals and alloys (ie. Al,Mg,Zn and
Pb base alloys).
Aluminum Alloy (I.C Engine) pistons are
cast in metal molds.
Used in Permanent mold casting, Pressure
die casting, Centrifugal casting
63
7/31/15
SHELL MOLDING
Shell molds are produced with the help of
heated iron or steel patterns.

A mixture of fine sand and resin is used to
produce shells.
Shells are assembled to form the mold
which is poured with molten metal.
Shell molds produce exceptionally good
surface finish and dimensional accuracy.
Shell molding is suited to ferrous and nonferrous alloy castings.
64
7/31/15
INVESTMENT MOLDING OR LOST WAX

MOLDING
Molten wax is poured in the die and obtain a wax
pattern(a).
Then the wax pattern is pre-coated by repeatedly
dipping it into a slurry of a fine refractory material.
Pre-coating is done to impart good surface finish
to the casting.
Then the investment molding mixture is poured
around the pre-coated wax pattern (b).
A typical investment mixture consists of 91.2%
sand, 3.8% water, 6.5% primary calcium
phosphate and 2.3%MgO-mesh.
65
7/31/15
IM(contd.)
Allow the investment to harden.
Heat the mold in the furnace (at 200 to 300
F).
This further hardens the mold and melts
the wax (c).
The investment mold is then heated to
between 1000 and 1800 F and after
heating, the molten metal can be poured
into it (d).
66
7/31/15
CERAMIC MOLDING
Ceramic Mold is a variation of Investment
Mold.
If instead of Investment molding mixture, a
slurry composed of refractory sand and
ceramic binder is poured on the wax
pattern, it results in ceramic thin-wall shell.
Wax is removed in the same manner as
Investment Mold.
67
7/31/15
PLASTER MOLDS
Make a metal pattern or of any other
moisture resistant material.

Make a slurry of mixtures of gypsum or
plaster of paris, and ingredients such as
talc, asbestos fiber, silica flour etc., with
water.
The slurry is poured over the pattern and
is allowed to set.
Pattern is taken out and is heated in oven
to about 600F for several hours.
It removes moisture from the plaster mold
68
7/31/15
GRAPHITE MOLDS
They are used to make Titanium Alloys
castings.
Graphite molds are prepared by squeezing
the graphite mold material around the
pattern at 4 to 8.5 kg/cm2 pressure.
The mold is dried and fired at 1800 to
2000F.
Graphite have been used for casting of
railroad and car wheels.
69
7/31/15
SODIUM SILICATE-CO2 MOLDS OR

CO2 MOLDING
Mixture of silica sand and sodium silicate
binder is rammed around the pattern in the

mold box.
Carbon dioxide gas is forced into the mold
at about 1.4 to 1.5 kg/cm2.
Na2 Si O3 +CO2
Na2 CO3 + Si O2
(Silica Gel)
Silica GEL hardens and forms a bond
between the sand grains
70
7/31/15
TYPES OF CASTING
PROCESS
71
7/31/15
DIE CASTING
Die casting is a permanent mold casting process
in which the molten metal is injected into the mold

cavity at an increased pressure.
The mold used in the die casting process is called a die.
A die casting machine consists of four basic
elements:
1. Frame : Holds the die. The frame consists of a
stationary part holding a stationary die and a movable
part holding a movable die.
2. Source of molten metal : A Holding furnace for
feeding metal.
3. Die-casting die
4. Metal injecting mechanism.
72
7/31/15
HOT CHAMBER DIE CASTING
Cycle in hotchamber casting:

(1) with die closed and plunger withdrawn, molten metal
flows into the chamber
73
7/31/15
Cycle in hotchamber casting:

(2) plunger forces metal in chamber to flow into die,
maintaining pressure during cooling and solidification
74
7/31/15

Metal is melted in a container, and a piston
injects liquid metal under high pressure

into the die
High production rates - 500 parts per hour
Applications limited to low meltingpoint
metals that do not chemically attack
plunger and other mechanical components
Casting metals: zinc, tin, lead, and
magnesium
75
7/31/15
COLD CHAMBER DIE CASTING

Molten
76
metal is poured into unheated

chamber from external melting container,
and a piston injects metal under high
pressure into die cavity
High production but not usually as fast as
hotchamber machines because of pouring
step
Casting metals: aluminum, brass, and
magnesium alloys
Advantages of hotchamber process favor
MATHEW
SAMUEL,
LECTURER
SOE CUSAT
its use
on
low meltingpoint
alloys (zinc,7/31/15
tin,
COLD CHAMBER DIE CASTING
77
VIDEO
MATHEW
SAMUEL, LECTURER SOE CUSAT
7/31/15
CENTRIFUGAL CASTING
In
Centrifugal Casting liquid metal is

introduced into a rotating mold so that
metal being poured is thrown to the outer
surface of the mold cavity.
Casting cools and solidifies from outside
towards the axis of rotation.
78
7/31/15
ADVANTAGES OF CENTRIFUGAL CASTINGS :

Castings produced are sound.
Rejection is less.
Production rate is sufficiently high.
Thin and intricate shapes can be cast.
Directional solidification is obtained.
DISADVANTAGES
All shapes cannot be cast.
Initial investment is more.
79
7/31/15
TYPES OF CENTRIFUGAL CASTINGS
True Centrifugal Casting.

Semi-Centrifugal Casting.
Centrifuge Casting.
80
7/31/15
TRUE CENTRIFUGAL CASTING

True
Centrifugal Casting is used for making

castings having more or less outer symmetrical
shape.
To cast a hollow cylinder for example a
cylindrical mold is made to rotate about its own
axis at a speed such that the metal being poured
is thrown to the outer surface of the mold cavity.
The metal solidifies in the form of a hollow
cylinder.
Since the metal is always pushed outward
because of the centrifugal force, no cores needs
to be used for making concentric hole.
81
7/31/15
SEMI-CENTRIFUGAL CASTING
Like Centrifugal castings, Semi-centrifugal
castings also uses the rotation of the mold about its axis.
Unlike True Centrifugal Casting, a core is used to form a
central cavity, for producing internal shapes that could

not be formed by any other method.
Semi- Centrifugal Casting technique is used to produce
castings which are symmetric about the axis of rotation.

Gear
blanks, wheels
Centrifugal castings.
82
are
produced
using
Semi-
7/31/15
CENTRIFUGE CASTING OR PRESSURE

CASTING
Parts which are not symmetric about any
axis of rotation can be cast using a group of

molds arranged in a circle to balance each
other.
The set up is revolved around the center of
the circle to induce pressure on the metal
in the molds.
Variety of smaller shapes can be cast.
Molten metal is passed to the mold cavities
through a central sprue.
83
7/31/15
SLUSH CASTING
Similar to Rotational Molding
Slush poured into mold
Slush is made from a
mixture of resin and
plastisols
Mold rotated
Part forms on surface of mold
Part removed
Slush
molding is an excellent method of

producing open, hollow objects, including rain
boots, shoes, toys, dolls and automotive
products, such as protective skin coatings on
arm rests, head rests and crash pads.
VIDEO
84
7/31/15
INVESTMENT CASTING
LOST WAX METHOD
****ALREADY DISCUSSED****
85
7/31/15
CASTING DEFECTS
86
7/31/15
CASTING DEFECTS
Imperfections in the castings is called as
Defects or Flaws in castings.

Classification of defects :
87
7/31/15
CLASSIFICATION OF CASTING
DEFECTS
1.DEFECTS CAUSED BY PATTERNS
MOLDING BOX EQUIPMENTS.
AND
Mismatch or Mold Shift : Castings does not
match at the parting line.

There is a mismatch of the top and bottom
parts of the casting.
Fins, Flash and Strains : Occur at the parting
88
line and result in excess metal which has to be

removed.
Crush : Displacement of sand while closing the
mold, thereby deforming the mold surface.
Causes
: Excess
weight cope portion mold.7/31/15
MATHEW
SAMUEL, LECTURER
SOE CUSAT
2. DEFECTS DUE TO IMPROPER

MOLDING AND CORE MAKING
MATERIALS.
BLOW HOLES :
Blow holes are smooth round holes which are not visible
from outside. Blow Holes are entrapped gas bubbles with
smooth walls.
Causes : Excess moisture, less permeability etc.
DROP :
A Drop occurs when cope surface cracks and breaks, thus
the pieces of sand fall into the molten metal.
Causes : Low Green Strength, low strength of mold.
SCAB :
It is the penetration of molten metal into the molding
material.
Causes : Too fine sand, uneven mold ramming etc.
89
7/31/15
DEFECTS DUE TO IMPROPER MOLDING

AND CORE MAKING MATERIALS (contd.)
PIN HOLES :
They are small holes revealed on the surface of a

casting.
Causes : High Moisture content of the sand, faulty
metals.
HOT TEARS :
They are internal or external cracks on castings

occurring due to unwanted cooling stresses.
Causes : Very hard ramming, faulty metal, faulty
design of casting, too much shrinkage of metal
while solidifying.
90
7/31/15
3. DEFECTS CAUSED BY MOLDING,

CORE MAKING, GATING ETC.
Hot Tears, Shifts,Fins and Flash, Crush
Cold Laps (Shuts) and Misrun :
If the molten metal is too cold, entire mold
91
cavity may not be filled during pouring before

the metal starts solidifying and the result is
Misrun. The defect may appear like a crack.
If molten metal enters through two or more
ingates or otherwise if two streams of metal
which are too cold, physically meet in the mold
cavity which do not fuse together, they
develop Cold Shut Defect.
Causes : Too cold molten metal, too thin
casting sections, too small gates, etc.
7/31/15
DEFECTS DUE BY MOLDING, CORE

MAKING, GATING ETC (contd.)
SLAG HOLES : They are smooth depressions
on the surface of castings. Slag Holes result

when slag enters the mold cavity.
SHRINKAGE DEFECTS : Molten Metals shrink
as they solidify. If this shrinkage is not

compensated by risers, voids will occur on
the surface or inside.
92
7/31/15
4. DEFECTS OCCURRING WHILE CLOSING AND

POURING THE MOLDS.
Shift or Mismatch, Misrun, Cold Laps or
Cold Shifts
INCLUSIONS:
Any separate undesirable foreign material

present in the metal of a casting is called
Inclusion. An inclusion may be oxides, slag
etc.
93
7/31/15
5. DEFECTS CAUSED BY THE MOLTEN

METAL.
MISRUNS, COLD SHUTS
SAND CUTS AND WASHES :
94
Molten metal as it flows over the mold and cores surfaces,

erodes the same and results in defects called Cuts and
Washes.
Causes: Weak Sand, Soft ramming etc.
FUSION :
Sand may fuse and stick to the casting resulting in rough
surface to the casting.
Causes : Too high molten metal temperature.
SHOT METAL :
If molten metal is relatively low temperature during pouring
into mold, a few small particles get separated from main
stream, they solidify and form shots. These shots, if do not
fuse with rest of molten metal, get embedded in the casting
causing a defect called Shot Metal.
7/31/15
6. DEFECTS OCCURRING WHILE

FETTLING(CLEANING) :
Sand and scales not properly removed from
castings, distorted castings not properly
removed.
7. DEFECTS DUE TO FAULTY HEAT

TREATMENT. : Uncontrolled heating, fast
cooling rates may cause cracking of brittle
castings.
95
7/31/15
INSPECTION OF CASTING
96
7/31/15
1. VISUAL INSPECTION
Most surface defects can be seen
2. PRESSURE TEST
The casting is filled with pressurized air after closing all
the openings
E.g. gear boxes, pressure vessels, look for leaks by
submerging in special liquids
Pressurized oil can also be used in some cases
3. RADIOGRAPHIC EXAMINATION
Usually x-rays or g rays
x-ray method is used for voids, non metallic inclusions,
porosity, cracks.
Defects appear darker than surrounding
97
7/31/15
4. ULTRASOUND EXAMINATION
Ultrasound across the casting
Sound transmitted across homogenous metals
However discontinuities reflect sound back.
5. DYE PENETRATION INSPECTION
To detect invisible surface defects in non magnetic
castings
A dye of fluorescent material is sprayed or applied
near the surface. The surface is then wiped and
viewed in darkness
Cracks will be visible
98
7/31/15
6. MAGNETIC PARTICLE INSPECTION
Induce magnetic field through section under
inspection
Powdered Ferro-magnetic magnetic material is
spread onto the surface
Voids or cracks result in abrupt changes in
permeability of material leads to leakage in
magnetic field
Particles concentrate on the disrupted field or
on the crack.
99
7/31/15
END OF THE MODULE
100
7/31/15

Module-3 Metal Casting

Încărcat de

Informații document

Descriere originală:

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Module-3 Metal Casting

Încărcat de

Drepturi de autor:

Formate disponibile

MODULE : 3

into a hollow mould until the material cools into a

forced to flow into a die cavity and allowed to

process Engine Block, Machine tool parts, etc.

MATHEW SAMUEL, LECTURER SOE CUSAT

pattern is used to make the mold.

prepare the cavity into which molten material will be

mold is made by packing some readily formed

After the pattern is withdrawn, its imprint leaves the mold

cavity , that is ultimately filled with metal to become the

Steps involved in casting process

MATHEW SAMUEL, LECTURER SOE CUSAT

MATHEW SAMUEL, LECTURER SOE CUSAT

used to prepare the cavity into which molten

MATHEW SAMUEL, LECTURER SOE CUSAT

PROPERTIES OF PATTERN MATERIAL

should be easily shaped, worked,

MATHEW SAMUEL, LECTURER SOE CUSAT

MATHEW SAMUEL, LECTURER SOE CUSAT

MATHEW SAMUEL, LECTURER SOE CUSAT

MATHEW SAMUEL, LECTURER SOE CUSAT

SINGLE PIECE/SOLID PATTERN:

piece because of the difficulties associated

So that one part will produce the lower

the Parting Line

LOOSE PIECE PATTERN

they are embedded in the molding sand.

loose pieces for facilitating their removal

MATHEW SAMUEL, LECTURER SOE CUSAT

MATCH PLATE PATTERN

portions mounted on opposite sides of a

MATHEW SAMUEL, LECTURER SOE CUSAT

patterns having attached gates and

MATHEW SAMUEL, LECTURER SOE CUSAT

COPE AND DRAG PATTERNS

pattern having the cope and drag

Used in production of large castings.

pattern is mounted on a separate molding

MATHEW SAMUEL, LECTURER SOE CUSAT

large castings of circular sections and

MATHEW SAMUEL, LECTURER SOE CUSAT

Pattern , in the sense that both types

segment and is used for producing circular

MATHEW SAMUEL, LECTURER SOE CUSAT

shapes(for example water pipes, turbine

MATHEW SAMUEL, LECTURER SOE CUSAT

FOLLOW BOARD PATTERN

used for various purposes.

MATHEW SAMUEL, LECTURER SOE CUSAT

within a set of regulations or for a specified purpose.

changes which will happen during the casting process,

MATHEW SAMUEL, LECTURER SOE CUSAT

TYPES OF PATTERN ALLOWANCES

MATHEW SAMUEL, LECTURER SOE CUSAT

MATHEW SAMUEL, LECTURER SOE CUSAT

The cast metal or alloy.

Pouring temp. of the metal/alloy.

Casting design aspects.

Molding conditions(i.e., mould materials and

MATHEW SAMUEL, LECTURER SOE CUSAT

Provided to compensate for machining on

Amount of allowance depends upon size

MATHEW SAMUEL, LECTURER SOE CUSAT