04 Casting

Minia University
Faculty of Engineering
Production Engineering and Mechanical Design Dept.
Lecture 4
Metal Casting Processes
Dr. Ahmed Badran

Plaster Mold Casting
Similar to sand casting except mold is made of plaster of Paris

(gypsum - CaSO4-2H2O)
 In mold-making, plaster and water mixture is poured over

plastic or metal pattern and allowed to set
 Wood patterns not generally used due to extended contact
with water
 Plaster mixture readily flows around pattern, capturing its fine

details and good surface finish
Advantages and Disadvantages
 Advantages of plaster mold casting:

 Good accuracy and surface finish
 Capability to make thin cross-sections
 Disadvantages:
 Mold must be baked to remove moisture, which can cause
problems in casting
 Mold strength is lost if over-baked
 Plastermolds cannot stand high temperatures, so limited to
lower melting point alloys
Ceramic Mold Casting
Similar to plaster mold casting except that mold is made of

refractory ceramic material that can withstand higher temperatures
than plaster
 Can be used to cast steels, cast irons, and other high-temperature
alloys
 Applications similar to those of plaster mold casting except for the
metals cast
 Advantages (good accuracy and finish) also similar
Permanent Mold Casting Processes
 Economic disadvantage of expendable mold casting: a

new mold is required for every casting
 In permanent mold casting, the mold is reused many times
 The processes include:
 Basic permanent mold casting
 Die casting
 Centrifugal casting
The Basic Permanent Mold Process
Uses a metal mold constructed of two sections designed for

easy, precise opening and closing
The Basic Permanent Mold Process
 Molds used for casting

lower melting point alloys
are commonly made of
steel or cast iron
 Molds used for casting
steel must be made of
refractory material, due
to the very high pouring
temperatures
Permanent Mold Casting
Steps in permanent mold casting:

(1) mold is preheated and coated
Permanent Mold Casting
Steps in permanent mold casting:

(2) cores (if used) are inserted and mold is closed,
(3) molten metal is poured into the mold, where it solidifies.
Steps in permanent-mold casting
Advantages and Limitations
 Advantages of permanent mold casting:

 Good dimensional control and surface finish
 More rapid solidification caused by the cold metal mold results in
a finer grain structure, so castings are stronger
 Limitations:
 Generally limited to metals of lower melting point
 Simplerpart geometries compared to sand casting because of
need to open the mold
 High cost of mold
Applications of Permanent Mold
Casting
 Due to high mold cost, process is best suited to high

volume production and can be automated
 Typical parts: automotive pistons, pump bodies, and

certain castings for aircraft and missiles
 Metals commonly cast: aluminum, magnesium,

copper-base alloys, and cast iron
Die Casting
A permanent mold casting process in which molten

metal is injected into mold cavity under high pressure
 Pressure is maintained during solidification, then mold
is opened and part is removed
Die Casting
 Molds in this casting operation are called dies; hence the

name die casting
 Use of high pressure to force metal into die cavity is what
distinguishes this from other permanent mold processes
Die Casting Machines
 Designed to hold and accurately close two mold halves and

keep them closed while liquid metal is forced into cavity
 Two main types:
1. Hot-chamber machine
2. Cold-chamber machine
Hot-Chamber Die Casting
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 not uncommon
 Applications limited to low melting-point metals that do not
chemically attack plunger and other mechanical components
 Casting metals: zinc, tin, lead, and magnesium
Metal is melted in a container,

and a piston injects liquid metal
under high pressure into the die
Cycle in hot-chamber casting: (1) with die closed and plunger withdrawn, molten
metal flows into the chamber
Cycle in hot-chamber casting: (2) plunger forces metal in chamber to flow

into die, maintaining pressure during cooling and solidification.
Cycle in hotchamber
casting

04 Casting

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Minia University

Dr. Ahmed Badran

Similar to sand casting except mold is made of plaster of Paris

 In mold-making, plaster and water mixture is poured over

 Plaster mixture readily flows around pattern, capturing its fine

 Advantages of plaster mold casting:

Similar to plaster mold casting except that mold is made of

 Economic disadvantage of expendable mold casting: a

Uses a metal mold constructed of two sections designed for

 Molds used for casting

Steps in permanent mold casting:

Steps in permanent mold casting:

 Advantages of permanent mold casting:

 Due to high mold cost, process is best suited to high

 Typical parts: automotive pistons, pump bodies, and

 Metals commonly cast: aluminum, magnesium,

A permanent mold casting process in which molten

 Molds in this casting operation are called dies; hence the

 Designed to hold and accurately close two mold halves and

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

Metal is melted in a container,

Cycle in hot-chamber casting: (2) plunger forces metal in chamber to flow

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