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Expendable mold casting involves the use of temporary, non-reusable molds. These methods
include: (1) sand casting, (2) plaster mold casting, (3) shell molding, (4) investment casting, (5) waste
molding of plaster and (6) evaporative-pattern casting.
Among these methods, sand casting and lost-wax casting (investment casting) are mostly
used.
Non-expendable mold casting differs from expendable processes in that the mold need not
be reformed after each production cycle. This technique includes at least four different methods:
(1) permanent casting, (2) die casting, (3) centrifugal casting, and (4) continuous casting.
Among these methods, permanent casting and die casting are mostly used.
Examples of Metal Casting (Lost-Wax Casting)
The resins are named by analogy with plant resins, but are synthetic monomers for making polymer
plastics. The so-called synthetic resins used include (1) polystyrene resin, (2) polyurethane resin, (3)
epoxy resin, (4) unsaturated polyester resin, (5) acrylic resin and (6) silicone resin.
A flexible mold can be made of latex rubber, room temperature vulcanized silicone rubber or other
similar materials at relatively low cost, but can only be used for a limited number of castings.
The simplest method is gravity casting where the resin is poured into the mold and pulled down into
all the parts by gravity. When the two part resin is mixed air bubbles tend to be introduced into the liquid
which can be removed in a vacuum chamber. The casting can also be done in a vacuum chamber (when
using open molds) to either extract these bubbles, or in a pressure pot, to reduce their size to the point
where they aren't visible. Pressure and/or centrifugal force can be used to help push the liquid resin into
all details of the mold. The mold can also be vibrated to expel bubbles.
Examples of Resin Casting (The Moldmaking Process)
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Glossary
aerodynamics – the study of the properties of moving air, and especially of the interaction between the
air and solid bodies moving through it
aircraft – any machine supported for flight in the air by buoyancy or by the dynamic action of air on its
surfaces
airframe – mechanical structure of an aircraft which includes the fuselage, wings and undercarriage and
excludes the propulsion system
aviation – the practical aspect or art of aeronautics, being the design, development, production,
operation and use of aircraft, especially heavier than air aircraft
casting – a manufacturing process in which a liquid material is usually poured into a mold, which
contains a hollow cavity of the desired shape, and then allowed to solidify
catalyst – a substance that increases the rate of a chemical reaction without itself undergoing any
permanent chemical change
composite – material made from two or more constituent materials with significantly
different physical or chemical properties that, when combined, produce a material with characteristics
different from the individual components
Glossary
expendable – designed to be used only once and then abandoned or destroyed
fabrication – the building of metal structures by cutting, bending, and assembling processes. It is a
value added process that involves the construction of machines and structures from various raw
materials
forge – make or shape a metal object by heating it in a fire or furnace and beating or hammering it
gravity –the force that attracts a body toward the center of the earth, or toward any other physical body
having mass. For most purposes Newton's laws of gravity apply, with minor modifications to take the
general theory of relativity into account
heat-treating – a group of industrial and metalworking processes used to alter the physical, and
sometimes chemical, properties of a material
machining – any of various processes in which a piece of raw material is cut into a desired final shape
and size by a controlled material-removal process
mold – a hollow container used to give shape to molten or hot liquid material (such as wax or metal)
when it cools and hardens
monomer – a molecule that can be bonded to other identical molecules to form a polymer
Glossary
polymer – a substance that has a molecular structure consisting chiefly or entirely of a large number of
similar units bonded together
plaster mold casting – a method of producing aluminum or zinc castings by pouring liquid metal
into plaster (gypsum) molds
pressure – the continuous physical force exerted on or against an object by something in contact with
it.
resin – a sticky flammable organic substance, insoluble in water, exuded by some trees and other plants
riveting – join or fasten (plates of metal or other material) with a rivet or rivets
RTV silicone rubber – a type of silicone rubber made from a two-component system used for making
molds
sand casting – a metal casting process characterized by using sand as the mold material
vacuum – a space entirely devoid of matter.
welding – join together (metal pieces or parts) by heating the surfaces to the point of melting using a
blowtorch, electric arc, or other means, and uniting them by pressing, hammering, etc.
Question & Answer
1) What is casting?
Casting is manufacturing process in which a liquid material is usually poured
into a mold, which contains a hollow cavity of the desired shape, and then allowed to
solidify.
6) What is a mold?
A mold is a hollow container used to give shape to molten or hot liquid
material (such as wax or metal) when it cools and hardens
8) What are the two main categories of the modern casting process?
The two main categories of the modern casting process is the expendable
mold and non-expendable mold casting.
Question & Answer
9) What are the different methods of expendable mold casting?
The methods of expendable mold casting include: (1) sand casting, (2) plaster
mold casting, (3) shell molding, (4) investment casting, (5) waste molding of plaster
and (6) evaporative-pattern casting
10) What are the different methods of non-expendable mold casting?
The methods of non-expendable mold casting include: (1) permanent casting,
(2) die casting, (3) centrifugal casting, and (4) continuous casting.
19) Why are magnesium alloys castings used for aerospace applications?
Magnesium alloy castings have a superior corrosion performance.
20) What are the properties of magnesium alloys?
Magnesium Alloy offers: (1) light weight, (2) low density, (3) excellent high temperature
mechanical properties and (4) good to medium corrosion resistance.
21) Why are magnesium, titanium and aluminum alloys used for aviation-grade casting?
This is due to the fact that they are lightweight and can operate under increasingly
demanding conditions.
Question & Answer
22) Why are titanium alloys superior to aluminum and magnesium alloys?
Titanium alloys are a preferred choice over Aluminum and Stainless steel
because it offers the distinct advantages of: (1) light weight, (2) high strength and (3)
increased payloads.
25) How does casting help in the construction and repair of aircraft ?
Casting helps aircraft fabricators create high quality copies of multiple
components in a relatively short amount of time.
COMMERCIAL AIRCRAFT DEMAND
Airbus Boeing
39,620
33,000
Boeing
Airbus
$5,900,000,000,000.00
Value of Aircraft
$5,200,000,000,000.00
PROJECTED AVERAGE ANNUAL GLOBAL
COMMERCIAL PASSENGER AIR TRAFFIC
GROWTH RATE (FROM 2016 TO 2035)
Airbus Boeing
4.8%
4.5%
Growth Rate
Conclusion and Summary
Casting is simply one of the methods we use to create aircraft. As
aviators and airmen we can all agree that the myriad of methods of aircraft
fabrication are of great importance. Almost 100 years ago, the ancient casting
method helped mankind enter the era of powered, heavier-than-air flight
when it was used to make the complex cast-aluminum crankcase and cylinder
block of the engine that Charles Taylor built for the Wright Brothers. It goes to
show that the mastery of a particular fabrication process, no matter how
simple, can pave the way for greater innovations.
Bibliography
• http://aviationweek.com/shownews/airbus-and-boeing-are-bullish-commercial-aircraft-
demand
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Springer, ISBN 978-0-387-74609-8.
• Ravi, B (2010), Metal Casting: Computer-aided Design and Analysis (1st ed.), PHI, ISBN 81-
203-2726-8.
Acknowledgement