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Lab Report 2

The document describes a lab report on the sand casting process. It details the objectives, materials, theory, procedures, observations, and conclusions of casting an aluminum alphabet A. Key steps included creating a sand mold, pouring molten aluminum, allowing it to cool and solidify, and then breaking the mold to retrieve the casting. The report discusses defects that can occur during solidification and environmental impacts of foundry waste.

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mamoona noreen
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© © All Rights Reserved
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76 views

Lab Report 2

The document describes a lab report on the sand casting process. It details the objectives, materials, theory, procedures, observations, and conclusions of casting an aluminum alphabet A. Key steps included creating a sand mold, pouring molten aluminum, allowing it to cool and solidify, and then breaking the mold to retrieve the casting. The report discusses defects that can occur during solidification and environmental impacts of foundry waste.

Uploaded by

mamoona noreen
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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THERMODYNAMICS

MANUFACTURING RESOURCE CENTER (MRC)

LAB REPORT 2: FOUNDRY

Submitted by: Hamna Anwaar Registration no: 335763


TITLE: Foundry

OBJECTIVE:

The objective of the practical is to develop understand about the casting method.

APPARATUS:

 Mold box (cope and drag)


 Parting Sand
 Mold (a Mixture of river sand and molasses)
 Ramer
 Runner
 Riser
 Lifter
 Ladle

PRINCIPLE:

Casting is 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. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process.

THEORY:

Metal casting is the process in which molten metal is poured into a mold and allowed to solidify into an
object. The object that solidifies is called a casting. Sand casting is defined as pouring of molten metal
into a sand mold and allowing it to solidify in the mold.

Sand casting is the most widely used metal casting process in manufacturing and almost all casting
metals can be sand cast. A few examples of modern items manufactured by the sand casting processes
are gears, dies used in the packing industry, cylinder heads, pump housings, and valves. Sand molds can
be formed to create castings with fine exterior detail, inner cores, and other shapes. Nearly any metal
alloy can be sand cast.

Sand casting is one of the few available processes for metals with high melting temperatures such as
steels, nickel, and titanium. Because of its flexibility, heat resistance, and relatively low cost, sand casting
is the most widely used casting process.

PROCEDURE:

Mold-making:

 The first step in the sand casting process is to create the mold for the casting.
 A sand mold is formed by packing sand into each half of the mold (drag and cope).
 The sand is packed around the pattern, excess sand is removed with a bar called runner, which is
a replica of the external shape of the casting.
 The cope is removed from the drag so the pattern can be extracted from the mold.
 Pattern extraction is undertaken carefully to avoid breaking or distorting the newly formed mold
cavity. This is facilitated by designing a draft: a vertical taper perpendicular to the parting line.
When the pattern is removed, the cavity that will form the casting remains.
 Parting sand is often applied to the surfaces of the mold cavity in order to facilitate removal of
the casting.

Clamping:

 Once the mold has been made, it must be prepared for the molten metal to be poured.
 The surface of the mold cavity is covered with parting sand to facilitate the removal of the
casting.
 Then, the cores are positioned and the mold halves are closed and securely clamped together.
 It is essential that the mold halves remain securely closed to prevent the loss of any material.

Pouring:

 The molten metal is maintained at a set temperature in a furnace.


 After the mold has been clamped, the molten metal can be ladled from its holding container in
the furnace and poured into the mold.
 The pouring can be performed manually or by an automated machine. Enough molten metal
must be poured to fill the entire cavity and all channels in the mold.
 The filling time is very short in order to prevent early solidification of any one part of the metal.

Cooling:

 The molten metal that is poured into the mold will begin to cool and solidify once it enters the
cavity.
 When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is
formed. The desired cooling time can be estimated based upon the wall thickness of the casting
and the temperature of the metal.

Removal:

 After the predetermined solidification time has passed, the sand mold can simply be broken,
and the casting removed. This step, sometimes called shakeout can be done manually or by
automated machinery.

Defects:

 Most of the possible defects that can occur are a result of the solidification process. If some of
the molten metal cools too quickly, the part may exhibit shrinkage, cracks, or incomplete
sections. Preventative measures can be taken in designing both the part and the mold and will
be explored in later sections.

ENVIRONMENTAL SIGNIFICANCE:

 Some of the environmental issues associated with the industry are – emission of harmful and
poisonous gases, dust and particles and generation of waste pollutants.
 Hazardous Air pollutants (HAPS) include gases, which are generated when molds containing
carbon materials are subjected to high temperatures as happens in the pouring of cast metals. It
include both chemically bonded as well as green sand molds. Of all the hazardous air pollutants
released from poured castings, benzene is the largest.
 Foundry waste is an area that has important priority within the global foundry industry from
both the environmental point of view as well as economic point of view.
 In terms of volume, gaseous waste is the largest source from foundries. Some other type of
waste products generated by foundries include – liquid emissions, solid waste – sand waste,
investment casting waste, cleaning room waste and slag wastes.

OBSERVATIONS:

We cast an alphabet A. The casting was well solidified.

CONCLUSION AND DISCUSSION:

Sand casting is one of the oldest and most economical processes for creating metal parts and structures.
Controlling the structure and properties of green sands and cores is of great necessity to produce the
metal parts and structures with high quality.
We can use various metals such as aluminum and cast iron in this process. Our group used aluminum.
We can shape metal by melting them into a liquid, pouring the molten metal into a mold that we had
were provided. In our case the pattern was the alphabet A. As it cools, we removed the mold material
after the metal has solidified.

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