Casting Methods Tools & Process

Casting
Method
Advantages Disadvantages Recommended Application

Sand Casting
Least Expensive in small quantities (less Dimensional accuracy inferior to other Use when strength/weight ratio permits
than 100) processes, requires larger tolerances
Tolerances, surface finish and low machining
Ferrous and non - ferrous metals may Castings usually exceed calculated weight cost does not warrant a more expensive
be cast process
Surface finish of ferrous castings usually
Possible to cast very large parts. exceeds 125 RMS
Least expensive tooling
Permanent and Semi-permanent Mold Casting
Less expensive than Investment or Die Only non-ferrous metals may be cast by Use when process recommended for parts
Castings this process subjected to hydrostatic pressure

Dimensional Tolerances closer than Less competitive with Sand Cast process Ideal for parts having low profile, no cores and
Sand Castings when three or more sand cores are quantities in excess of 300
required
Castings are dense and pressure tight
Higher tooling cost than Sand Cast
Plaster Cast
Smooth "As Cast" finish (25 RMS) More costly than Sand or Permanent Use when parts require smooth "As Cast"
Mold-Casting surface finish and closer tolerances than
Closer dimensional tolerance than Sand possible with Sand or Permanent Mold
Cast Limited number of sources Processes

Intricate shapes and fine details Requires minimum of 1 deg. draft
including thinner "As Cast" walls are
possible

Large parts cost less to cast than by
Investment process
Investment Cast
Close dimensional tolerance Costs are higher than Sand, Permanent Use when Complexity precludes use of Sand or
Mold or Plaster process Castings Permanent Mold Castings
Complex shape, fine detail, intricate
core sections and thin walls are possible The process cost is justified through savings in
machining or brazing
Ferrous and non-ferrous metals may be
cast Weight savings justifies increased cost

As-Cast" finish (64 - 125 RMS)
Die Casting
Good dimensional tolerances are Economical only in very large quantities Use when quantity of parts justifies the high
possible due to high tool cost tooling cost

Excellent part-part dimensional Not recommended for hydrostatic Parts are not structural and are subjected to
consistency pressure applications hydrostatic pressure

Parts require a minimal post machining For Castings where penetrant (die) or
radiographic inspection are not required.

Difficult to guarantee minimum
mechanical properties

Some of the most important foundry equipment are

1. Laboratory
1.1 Abrasive Discs
1.2 Carbon Determinators
1.3 Chemical Analysis Instruments
1.4 Core Hardness Testers
1.5 Gas Analysis Equipment
1.6 Hardness Testing Equipment
1.7 Hydrogen Porosity Tester
1.8 Laboratory Chemicals
1.9 Laboratory Furnaces
1.10 Laboratory Ovens
1.11 Pyrometers
1.12 Radiographic Equipment
1.13 Sand Testing Equipment
1.14 Spectrographic Equipment
1.15 Stress Analysis Equipment
1.16 Surface Measuring Equipment
1.17 Temperature Indicating Materials
1.18 Temperature Recording & Control Devices
1.19 Tensile Testing Machines
1.20 Thermocouple Sheaths
1.21 Analytical Equipment
1.22 Thermocouples

2. Mold, Core & Sand
2.1 Chip Dryers
2.2 Carbon Raisers
2.3 Cupola Injectors
2.4 Cupola Blowers
2.5 Cupola Chargers & Auxiliaries
2.6 Cupola Fluxes
2.7 Cables
2.8 Immersion Bells
2.9 Molding Machines
2.10 Cupola Control Equipment
2.11 Fluxes
2.12 Core Hangers
2.13 Hot Melt Aerators
2.14 Core Drawing Machines
2.15 Environmental Refractory Handling Systems
2.16 Deoxidizers
2.17 Core Binders
2.18 Sand Air Strippers
2.19 Core Extruding Machines
2.20 Molten Level Flow Control Systems
2.21 Mixers
2.22 Core Ovens
2.23 Gas Generators
2.24 Core Handling Equipment
2.25 Cupola Hot Blast Equipment

3. Cleaning & Finishing
4.1 Blasting

4. Melting, Pouring & Heat Treatment Equipment
6.1 Coke
6.2 Ductile Iron Converters
6.3 Furnaces
6.4 Chargers
6.5 Induction Heating Systems
6.6 Ingot Loaders
6.7 Ingot Pre-heaters
6.8 Inhibitors
6.9 Pouring Ladles
4.10 Pouring Equipment

5. Testing & Inspection
7.1 Radiographic Testing
7.2 Metallographic & Metallurgical Test Equipment
7.3 Nondestructive Test Equipment
7.4 Ultrasonic Test Equipment
7.5 X-Ray Diffraction Tubes

Sand Casting Process

Core Making Pattern
(if needed) Making

Preparation of
Sand Mold Making
Sand
Raw Solidification Removal of Cleaning &

Melting Pouring
Material & Cooling Sand Inspection

Casting Methods Tools & Process

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Casting

Advantages Disadvantages Recommended Application

Raw Solidification Removal of Cleaning &

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