Casting is a manufacturing process by 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. Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods Steps in Making Sand Castings 1. There are six basic steps in making sand castings: Pattern and core making. 2. Preparing the mold by using molding sand 3. Remove pattern 4. Melting and pouring of molten metal in the mold cavity 5. Allow the metal to cool and solidify 6. Break the sand mold nd remove the casting, clean and inspect the casting. Pattern Making The pattern is a physical model of the casting used to make the mold. The mold is made by packing some readily formed aggregate material, such as molding sand, around the pattern. When the pattern is withdrawn, its imprint provides the mold cavity, which is ultimately filled with metal to become the casting. If the casting is to be hollow, as in the case of pipe fittings, additional patterns, referred to as cores are used to form these cavities Core Making Cores are forms, usually made of sand, which are placed into a mold cavity to form the interior surfaces of castings. Thus the void space between the core and mold-cavity surface is what eventually becomes the casting Molding Molding consists of all operations necessary to prepare a mold for receiving molten metal. Molding usually involves placing a molding aggregate around a pattern held with a supporting frame, withdrawing the pattern to leave the mold cavity, setting the cores in the mold cavity and finishing and closing the mold. Melting and Pouring The preparation of molten metal for casting is referred to simply as melting. Melting is usually done in a specifically designated area of the foundry, and the molten metal is transferred to the pouring area where the molds are filled.

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 improve 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. The use of an expensive pattern is justified when the quantity of castings required is substantial. Functions of the Pattern 1. A pattern prepares a mold cavity for the purpose of making a casting. 2. A pattern may contain projections known as core prints if the casting requires a core and need to be made hollow. 3. Runner, gates, and risers used for feeding molten metal in the mold cavity may form a part of the pattern. 4. Patterns properly made and having finished and smooth surfaces reduce casting defects. 5. 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: 1. Easily worked, shaped and joined 2. Light in weight 3. Strong, hard and durable 4. Resistant to wear and abrasion 5. Resistant to corrosion, and to chemical reactions 6. Dimensionally stable and unaffected by variations in temperature and humidity 7. Available at low cost The usual pattern materials are wood, metal, and plastics. The most commonly used pattern material is wood, since it is readily available and of low weight. Also, it can be easily shaped and is relatively cheap. The main disadvantage of wood is its absorption of moisture, which can cause distortion and dimensional changes. Hence, proper seasoning and upkeep of wood is almost a pre-requisite for large- scale use of wood as a pattern material. Choice of

pattern material depends essentially on the size of the casting, the number of castings to be made from the pattern, and the dimensional accuracy required. For very large castings, wood may be the only practical pattern material. Moulding sand being highly abrasive for large scale production, wood may not be suitable as a pattern material and one may have to opt for metal patterns. Because of their durability and smooth surface finish, metals such as aluminium and aluminium alloys, white metal, cast iron, steel, brass, bronze, lead alloys are most commonly used as pattern materials. Plastics are also used as pattern materials because of their low weight, easier formability, smooth surfaces and durability. They dont absorb moisture and are dimensionally stable and can be cleaned easily. The making of a plastic pattern can be done in sand clay moulds or moulds made of plaster of Paris. The most generally used plastics are cold setting epoxy resins with suitable fillers. With a proper combination it is possible to obtain a no shrink plastic material and as such double shrinkage allowances may not be required .Polyurethane foam(PUF), which is light and easily formed, can be used for light duty work for small number of castings.

Casting Terms 1. Flask: A metal or wood frame, without fixed top or bottom, in which the mold is formed. Depending upon the position of the flask in the molding structure, it is referred to by various names such as drag - lower molding flask, cope - upper molding flask, cheek - intermediate molding flask used in three piece molding. 2. Pattern: It is the replica of the final object to be made. The mold cavity is made with the help of pattern. 3. Parting Line: This is the dividing line between the two molding flasks that makes up the mold. 4. Bottom Board: This is a board normally made of wood which is used at the start of the mould making. The pattern is first kept on the bottom board, sand is sprinkled on it and then the ramming is done in the drag. 5. Molding Sand: Sand, which binds strongly without losing its permeability to air or gases. It is a mixture of silica sand, clay and moisture in appropriate proportions. 6.Facing Sand: The small amount of carbonaceous material sprinkled on the inner surface of the mold cavity to give a better surface finish to the castings. 7.Backing Sand: it is what constitutes most of the refractory material found in the mould. This is made up of used and burnt sand. 8.Core: A separate part of the mold, made of sand and generally baked, which is used to create openings and various shaped cavities in the castings. 9.Pouring basin: A small funnel shaped cavity at the top of the mold into which the molten metal is poured. 10.Sprue: The passage through which the molten metal, from the pouring basin, reaches the mold cavity. In many cases it controls the flow of metal into the mold. 11.Runner: The channel through which the molten metal is carried from the sprue to the gate. 12.Gate: A channel through which the molten metal enters the mold cavity. 13.Cha plet s: Chaplets are used to support the cores inside the mold cavity to take care of its own weight and overcome the metallostatic force. 14.Chill: These are metallic objects which are placed in the mould to increase the cooling rate of castings to provide uniform or desired cooling rate. 15.Riser: A column of molten metal placed in the mold to feed the castings as it shrinks and solidifies. Also known as "feed head". 16.Vent: Small opening in the mold to facilitate escape of air and gases.

Advantages The metal casting process is extensively used in manufacturing because of its many advantages. 1. Molten material can flow into ve ry small sections so that intricate shapes can be made by this process. As a result, many other operations, such as machining,forging, and welding, can be minimized or eliminated. 2. It is possible to cast practically any material that is fer rous or non-ferrous. 3. As the metal can be placed exactly where it is required, large saving in weight can be achieved. 4. 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. 5. There are certain parts made from metals and alloys that can only be processed this way. 6. Size and weight of the product is not a limitation for the casting process. Limitations 1. 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. 2. The metal casting process is a labor intensive process