Chapter 3 Casting
Chapter 3 Casting
Chapter 3 Casting
Foundry Technology
INTRODUCTION
The metal casting industry plays a key role in all the
major sectors of our economy. There are castings in
locomotives, cars trucks, aircraft, office buildings,
factories, schools, and homes. Figure some metal cast
parts.
Casting means pouring molten metal into a mold with a cavity of the
shape to be made, and allowing it to solidify. When solidified, the
desired metal object is taken out from the mold either by breaking the
mold or taking the mold apart. The solidified object is called the
casting.
By this process, produce parts can be given strength and rigidity
frequently not obtain by any other manufacturing process.
The mold, into which the metal is poured, is made of some heat
resisting material. Sand is most often used as it resists the high
temperature of the molten metal. Permanent molds of metal can also be
used to cast products.
Advantages
Molten material can flow into very small sections so
that difficult shapes can be made by this process. As
a result, many other operations, such as machining,
forging, and welding, can be minimized or
eliminated.
It is possible to cast practically any material that is
ferrous or non-ferrous
The necessary tools required for casting molds are
very simple and inexpensive. As a result, for
production of a small lot, it is the ideal process.
There are certain parts made from metals and alloys
that can only be processed this way.
Size and weight of the product is not a limitation for
the casting process.
Limitations
Dimensional accuracy and surface finish of the
castings made by sand casting processes are a
limitation to this technique. Many new casting
processes have been developed which can take into
consideration the aspects of dimensional accuracy
and surface finish. Some of these processes are die
casting process, investment casting process, vacuum-
sealed molding process, and shell molding process.
Casting Terms
Figure : Mold Section showing some casting terms
Cleaning
Cleaning refers to all operations necessary to the removal
of sand, scale, and excess metal from the casting. Burned-
on sand and scale are removed to improved the surface
appearance of the casting. Excess metal, in the form of
fins, wires, parting line fins, and gates, is removed.
Inspection of the casting for defects and general quality is
performed.
Pattern
The pattern is the principal tool during the casting process. It
is the replica of the object to be made by the casting process,
with some modifications. The main modifications are the
addition of pattern allowances, and the provision of core
prints. If the casting is to be hollow, additional patterns called
cores are used to create these cavities in the finished product.
The quality of the casting produced depends upon the material
of the pattern, its design, and construction. The costs of the
pattern and the related equipment are reflected in the cost of
the casting
Functions of the Pattern
A pattern prepares a mold cavity for the purpose of making
a casting.
A pattern may contain projections known as core prints if
the casting requires a core and need to be made hollow.
Runner, gates, and risers used for feeding molten metal in
the mold cavity may form a part of the pattern.
Patterns properly made and having finished and smooth
surfaces reduce casting defects.
A properly constructed pattern minimizes the overall cost of
the castings.
Pattern Material
Patterns may be constructed from the following materials.
Each material has its own advantages, limitations, and field of
application. Some materials used for making patterns are:
wood, metals and alloys, plastic, plaster of Paris, plastic and
rubbers, wax, and resins. To be suitable for use, the pattern
material should be:
Easily worked, shaped and joined
Light in weight
Strong, hard and durable
Resistant to wear and abrasion
Resistant to corrosion, and to chemical reactions
Dimensionally stable and unaffected by variations in
temperature and humidity
Available at low cost
Pattern Allowances
Pattern allowance is a vital feature as it affects the
dimensional characteristics of the casting.
Thus, when the pattern is produced, certain allowances must
be given on the sizes specified in the finished component
drawing so that a casting with the particular specification
can be made.
The selection of correct allowances greatly helps to reduce
machining costs and avoid rejections.
The allowances usually considered on patterns and core
boxes are as follows:
1. Shrinkage or contraction allowance
2. Draft or taper allowance
3. Machining or finish allowance
4. Distortion or camber allowance
5. Rapping allowance
Shrinkage or Contraction Allowance
Surface Finish of the castings obtained by this process is not good and
machining is often required to achieve the finished product.
Sand Mold Making Procedure
The procedure for making mold of a cast iron wheel
is shown in (Figure 8(a),(b),(c)).
The first step in making mold is to place the pattern
on the molding board.
The drag is placed on the board ((Figure 8(a)).
Dry facing sand is sprinkled over the board and
pattern to provide a non sticky layer.
The drag is completely filled with molding sand.
The sand is then firmly packed in the drag by means
of hand rammers. The ramming must be proper i.e. it
must neither be too hard or soft.
Figure 8 (a, b, c): Sand Mold Making Procedure
Figure 8 (c)
After the ramming is over, the excess sand is leveled
off with a straight bar known as a strike rod.
With the help of vent rod, vent holes are made in the
drag to the full depth of the flask as well as to the
pattern to facilitate the removal of gases during
pouring and solidification.
The finished drag flask is now rolled over to the
bottom board exposing the pattern.
Cope half of the pattern is then placed over the drag
pattern with the help of locating pins. The cope flask
on the drag is located aligning again with the help of
pins ( (Figure 8 (b)).
The dry parting sand is sprinkled all over the drag and
on the pattern.
A sprue pin for making the sprue passage is located at
a small distance from the pattern. Also, riser pin, if
required, is placed at an appropriate place.
The operation of filling, ramming and venting
of the cope proceed in the same manner as
performed in the drag.
The sprue and riser pins are removed first and
a pouring basin is scooped out at the top to
pour the liquid metal.
Then pattern from the cope and drag is
removed and facing sand in the form of paste
is applied all over the mold cavity and runners
which would give the finished casting a good
surface finish.
The mold is now assembled. The mold now is
ready for pouring (see ((Figure 8 (c)
Molding Properties
Refractoriness
It is the ability of the molding material to resist the
temperature of the liquid metal to be poured so that it does
not get fused with the metal. The refractoriness of the silica
sand is highest.
Permeability
During pouring and subsequent solidification of a casting, a
large amount of gases and steam is generated. These gases
are those that have been absorbed by the metal during
melting, air absorbed from the atmosphere and the steam
generated by the molding and core sand. If these gases are
not allowed to escape from the mold, they would be
entrapped inside the casting and cause casting defects. To
overcome this problem the molding material must be
porous. Proper venting of the mold also helps in escaping
the gases that are generated inside the mold cavity.
Green Strength
It is the strength of the sand in the green state.
A mold having good green strength will retain its shape, will
not distort.
Dry Strength
It is the strength of the sand in the dry state.
processes.
Flowability is the ability of the molding sand to get
Collapsibility
The molding sand should also have collapsibility so
1.Base Sand
Silica sand is most commonly used base sand. Other
base sands that are also used for making mold are
zircon sand, Chromite sand, and olivine sand. Silica
sand is cheapest among all types of base sand and it is
easily available.
2.Binder
Binders are of many types such as:
1.Clay binders,
2.Organic binders and
3.Inorganic binders
1.Clay binders are most commonly used binding agents mixed
with the molding sands to provide the strength. The most
popular clay types are:
Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O) and Bentonite
(Al2O3 4 SiO2 nH2O)
3.Moisture
Clay acquires its bonding action only in the presence of the
required amount of moisture. When water is added to clay, it
penetrates the mixture and forms a microfilm, which coats the
surface of each flake of the clay. The amount of water used
should be properly controlled.
Dry Sand Molding
When it is desired that the gas forming materials are
lowered in the molds, air-dried molds are sometimes
preferred to green sand molds. Two types of drying of
molds are often required.
1.Skin drying and
2.Complete mold drying.
In skin drying a firm mold face is produced. Shakeout
of the mold is almost as good as that obtained with
green sand molding. The most common method of
drying the refractory mold coating uses hot air, gas or
oil flame. Skin drying of the mold can be
accomplished with the aid of torches, directed at the
mold surface.