Manufacturing Technology-I

Subject Code : ME3C04

Lectures per week : 3 No.s
Dr. Abhinaba Roy
Assistant Professor
Mechanical Engineering Department
National Institute of Engineering
Mysore, Karnataka
 Introduction
What is Manufacturing ?
Manufacturing is the process of converting raw materials into
useful/valuable products

Technical Process
 Introduction
What is Manufacturing ?
Manufacturing is the process of converting raw materials into
useful/valuable products

Economical Process
 Introduction
Manufacturing includes :
Design of the product
Selection of raw materials
Sequence of processes to be followed

Manufacturing methods :
Casting/Forming – total deformation of the material into required shape
Welding – joining of two different parts using heat
Machining – removing of excess material from the parent structure
 Introduction
Product Lifecycle
 Introduction
Classification of
Engineering Materials

Materials that are used as raw

material for any sort of construction
or manufacturing in an organized way
of engineering application are known
as Engineering Materials.
 Introduction
Classification of
Manufacturing Processes
Introduction - Solidification Processes
What are Solidification Processes ?
Liquid material (metal/glass/polymer) is poured into a mold cavity which
matches the shape and size of the part to be manufactured.
Production method is completed after the liquid “solidifies” in the cavity.
 Introduction - Particulate Processing
What are Particulate Processes ?
Powdered metal/ceramics/polymers are pressed into a shape and then sintered.
These powders are squeezed into a die cavity at high pressure and then heated
at high temperature forcing individual particulates/powdered particles to bond.
Introduction – Deformation Processes
What are Deformation Processes ?
Deformation Processes transform solid materials from one shape into another.
Initial shape is usually a billet/sheet which can be either metallic or non-metallic.
Tools or dies are used to obtain the final geometry and required tolerances.
Examples : Rolling, Forging, Extrusion, Punching

Rolling Punching

Forging

Extrusion
Introduction – Material Removal Processes
What are Material Removal Processes ?
Material removal process is a type of manufacturing process in which the final
product is obtained by removing excess metal from the original workpiece.
Example :
Turning, Grinding, Milling, Drilling – conventional techniques
Electro discharge machining, water jet machining - nonconventional

Turning
Water Jet
Machining

Drilling
Solidification Processes
 Solidification Processes - Casting
Casting is a manufacturing process by which a liquid material is usually poured
into a mould, which contains a hollow cavity of the desired shape, and then
allowed to solidify.
 Casting Terminologies

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
Casting Process Flow Diagram
 Elements of Casting Process - Pattern
Pattern is a replica of the object to be cast.
This is used to prepare the cavity into which molten material is poured.
Quality of casting produced depends on its material, design and construction.
 Pattern Allowances
Pattern allowances are important factors to be considered during its design phase.

Because, final dimensions of casting are different from pattern because of reasons:

Shrinkage Allowance
Machining Allowance
Draft/Taper Allowance
Distortion Allowance
Rapping/Shake Allowance

Let’s understand how to perform a good casting with allowance types…..

 Pattern Allowances - Shrinkage
Shrinkage Allowance

Liquid shrinkage refers to reduction in volume when metal changes from liquid to
solid state. Riser are used to compensate this.

Solid shrinkage refers to reduction in volume when metal loses temperature in

solid state. To compensate this shrinkage allowance is used.

Pattern is made slightly bigger – this difference in size of the pattern is called
shrinkage allowance.
Amount of allowance depends upon type of material, its composition pouring
temperature etc.
Allowances for different materials

Contraction Allowance
Sl. No. Metals/Alloys
mm/meter

1. Grey cast iron 7 - 10.5

2. Malleable iron 15

3. Steel 20

4. Copper 16

5. Aluminium 16

6. Magnesium 18

7. Zinc 24
 Pattern Allowances - Machining
Machining Allowance

It is given to get better surface finish

Provided to compensate for machining on casting

Pattern is made slightly bigger in size

Amount of allowance depends upon size and shape of casting, type of material,
machining process to be used, degree of accuracy and surface finish required

A layer of 1.5 – 2.5 mm thick material is provided all around the casting
 Allowances for different materials

Dimensions Machining allowance

Material
(in mm) (in mm)

Upto 300 2.5

Cast Iron
300 to 600 4.0

Upto 300 1.5

Aluminium
300 to 600 3.0

Upto 300 3.0

Cast Steel
300 to 600 4.5
 Pattern Allowances
Draft/Taper Allowance

Provided to facilitate easy withdrawal of the pattern

Typically it ranges between 1 – 3⁰ for wooden patterns

 Allowances for different materials
Draft angle of surfaces
Pattern Height of the given surface (in degrees)
Material (in mm)
External Internal
Surface Surface
Upto 20 3.00 3.00
21 – 50 1.50 2.50
51 – 100 1.00 1.50
101 – 200 0.75 1.00
Wood
201 – 300 0.50 1.00
301 – 800 0.50 0.75
801 – 2000 0.35 0.50
Over 2000 --- 0.25
20 1.50 3.00
21 – 50 1.00 2.00
51 – 100 0.75 1.00
Metal / Plastic
101 – 200 0.50 0.75
201 – 300 0.50 0.75
301 - 800 0.35 0.50
 Pattern Allowances
Distortion Allowance

Due to non-uniform contraction and residual stresses casting shape changes.

For example :

A U-shaped casting will be distorted during cooling with legs diverging, instead of
parallel
To compensate, the pattern is made with legs converged but as the casting cools,
the legs straighten and remain parallel
 Pattern Allowances
Rapping/Shake Allowance

To remove the pattern out of mold cavity, it is slightly rapped or shaked to detach it
from the mould cavity

To compensate a negative allowance is given – pattern is made slightly smaller

 Casting Process
Casting is one of the Manufacturing Processes
- A shaped cavity is formed in the sand or metal.
- Molten metal is poured into the cavity slowly and allowed to cool.
- Cooled solid metal is separated from the mould.
- The solid metal will have the shape of the cavity and is known as casting.

Casting makes use of fusibility property of the material.

Fusibility is the property of the material wherein it becomes liquid on

heating and becomes solid on cooling.

The place where casting is carried out is known as Foundry.

Therefore, casting process can also be referred as foundry process.
 Classification of Casting/Foundry Process
1. Based on the type of metal being cast
- Ferrous foundry (deals with iron based metals and alloys)
- Non-ferrous foundry (deals with non-ferrous metals and alloys)

2. Based on the nature of foundry

- Jobbing foundry (produces small quantity of castings)
- Captive foundry (castings required for internal needs)
- Mechanized foundry (produces large number of castings)

3. Based on the total tonnage of castings produced

- Small sized foundry (20-50T/month)
- Medium sized foundry (50-100T/month)
- Large sized foundry (Upto 1000T/month)

4. Based on the type of mould used

- Sand casting (Sand is used to make the mould)
- Die casting (Metal is used to make the mould)
 Casting Process - Advantages & Limitations
Advantages :

• Components are produced to near final shape or near net shape

• Any type of metal or alloy can be easily cast
• Any size or shape can be easily produced
• Uniform properties are obtained in the casting throughout
• Process can be easily adopted to automation and mass production
• Castings are cheaper than components made by other processes

Limitations :

• Directional properties is difficult to achieve in the casting

• Some internal defects like pore, cracks, cannot be completely removed
• Cooling of metal takes more time
• More numbers of variables are involved : hence needs more attention
 Casting Process - Required Knowledge
Knowledge of following parameters are essential for the successful
production of casting :

• Knowledge of Design
• Knowledge of Metal flow
• Knowledge of Heat flow
• Knowledge of Metallurgy/Material Science
• Knowledge of Shop floor layout and functions

To successfully produce a high quality casting knowledge of

aforementioned fields are required.

Otherwise, the cast product may have multiple flaws !

 Casting Process - Components

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
 Casting Process - Components

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
 Casting Process - Components

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
 Casting Process - Components

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
 Casting Process - Components

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
 Casting Process - Gating System
Liquid Metal
Liquid Metal
overflows from here
poured here
 Casting Process - Gating System
Components of Gating System :

Pouring Cup  Pouring cup facilitates easy transfer of molten metal from
the ladle (container which contains the liquid metal) to the sprue without
any spillage.
 Casting Process - Gating System
Components of Gating System :

Sprue  It is a taper shaped vertical component which helps to transfer the

molten metal from pouring cup to runner without any aspiration.
 Casting Process - Gating System
Components of Gating System :

Sprue Base  It is an enlarged section (compared to sprue bottom) which

suppresses the flow velocity of molten metal and helps in changing its
direction from vertical to horizontal. (Advantageous for Metal flow !)
 Casting Process - Components

• Flask / Mould Box

• Pattern
• Parting line
• Bottom board
• Facing sand
• Moulding sand
• Parting sand
• Pouring basin
• Gate
• Riser
 Casting Process - Gating System
Components of Gating System :

Runner  It is a long horizontal channel which carries molten metal and

distribute it to the gates and ensures proper filling of the cavity.
 Casting Process - Gating System
Components of Gating System :

Gates/Ingates  These are small channels connecting the mold cavity and
the runner. The molten metal changes its direction and helps to uniformly
distribute molten metal by avoiding turbulent flow.
 Casting Process - Gating System
Functions of Gating System :

• A good gating system should help easy and complete filling of the mould
cavity
• It should fill the mould cavity with least amount of turbulence
• It should prevent mould erosion and gas pickup
• It should establish proper temperature gradient in the casting
• It should promote directional solidification
• It should regulate the rate of flow of metal into the mold cavity

Types of Gates :

• Top Gate
• Bottom Gate
• Parting line Gate
 Casting Process - Gating System

Choke area
 Casting Process - Gating System
Gating Ratio
Gating ratio refers to the relation between area of the choke to total area
of runner to total area of ingates.

If Ac = choke area
Ar = total runner area
Ag = total ingate area

Then Gating ratio = Ac : Ar : Ag

Gating ratio decides the nature of molten metal flow. It can be classified as:

• Pressurized System
• Unpressurized System
 Casting Process - Gating System
Gating Ratio
Gating ratio depends on the nature of the molten metal.

• Pressurized gating system is used for reactive metals like magnesium

alloys. Unpressurized gating system is used for normal metals like brass,
steel, aluminum etc.
• Example of Pressurized Gating system : 1:2:1, 1:0.75:0.50
Example of Unpressurized Gating system : 1:2:2, 1:3:3, 1:1:3
• Pressurized system is referred to as “Gate control system” since ingates
control the flow of metal
Unpressurized system is referred to as “Choke control system: since
choke controls the flow of metal
• Pressurized system has high metal velocity and results in turbulence
whereas Unpressurized system will have low metal velocity and results
in more streamlined flow of metal in the mould cavity
 Casting Process - Gating System
Gating Ratio ….. Contd.
Gating ratio depends on the nature of the molten metal.

• Pressurized gating system consumes less metal and yields more whereas
Unpressurized gating system consumes more metal and yield will be
slightly lower.

Sl. No. Metal Ratio

1. Steel 1 : 2 : 1.5
1:3:3
1:2:2
2. Gray Cast Iron 1:4:4
Pressurized System 1 : 1.3 : 1.1
3. Aluminium
Pressurized System 1:2:1
Unpressurized System 1:3:3
 Casting Process - Risers
Principle of Riser

After liquid metal is poured into the mould its starts to solidify.
When the liquid completely solidifies a volumetric contraction happens.
This happens for all metals and alloys.

Hence, shrinkage allowance is given to compensate and maintain required

dimension of the casting.

Riser is a reservoir of molten metal placed just above the solidifying metal
so that it can supply required quantity of liquid metal as it starts to solidify.
Casting Process - Risers
 Casting Process - Risers
Functions of a Riser

• Chief function of Riser is to supply the molten metal to the solidifying

casting and eliminate shrinkage cavity
• It should establish necessary temperature gradient to promote
directional solidification
• It should permit easy escape of air and gases
• It should solidify later than the casting
• It should promote minimum wastage of material

Types of Risers

• Open Riser
• Blind Riser
 Casting Process - Risers
Open Riser
An open riser is a riser provided in the mould cavity where the top
portion is open to the atmosphere. Therefore it is easier to mould.
An open riser can be classified as : Top riser and Side riser
 Casting Process - Risers
Blind Riser
A blind riser is a riser which is covered with the moulding sand and is
not exposed to the atmosphere directly. Blind risers are used in steel
castings and utilizes atmospheric pressure acting on the metal
through a core.
 Sand Casting vs Die Casting
Die Casting
Die casting is a process where liquid or molten metal is forced into a
die under high pressure. The “die” refers to the steel mold created in
the shape the product will be made. After the molten metal cools
down, the product is extracted and it becomes ready for another
pour.

Sand Casting
In sand casting the liquid metal is poured directly into a mold in the
sand and there is no high pressure involved. After the molten metal
solidifies and extracted from the sand mould it can not be reused
again.
 Sand Casting vs. Die Casting
Sand Casting Die Casting
This casting process employs mould This casting process employs a
made of sand permanent mould usually made of
metal
This process is characterized by pouring This process is characterized by forcing
molten metal down the sprue under molten metal under high pressure into
atmospheric pressure into the mould the mold cavity
cavity
The mold cavity is created using pre- The mold cavity is created using two
made patterns which are exact replica of hardened tool steel dies which have
the part to be cast been machined into shape
Sand casts are made using suitable sand Die casts are made from non-ferrous
types which are rammed and forced to metals like zinc, copper, aluminium,
acquire shape of the pattern magnesium and tin based alloys
Advantages: Sand Casting & Die Casting
Sand Casting Die Casting

Low capital investment means that Cost per unit is minimum, hence
short production runs are viable economical

Use of sand cores allows fairly It requires less floor space as

complex shapes to be cast compared to other casting processes

Large components can be produced Rate of production is high

Suitable for small batch production High surface finish is obtained and
often no further finishing is required
 Disadvantages: Sand Casting & Die Casting
Sand Casting Die Casting
Production of sand casting involves a large Production of die casting moulds involve
number of steps like casting design, pattern use of large amount of raw material,
making, moulding, melting, pouring, shake machining costs and heat treatment before
out etc. production could be started and hence
Since many parameters are involved in this require large capital investment
process, there are chances of defective beforehand. Therefore, if the mould fails
castings – which can not be reclaimed and then a huge cost is required to replace it
need to be redone
Sand castings are generally filled with Die castings are generally filled with defects
multiple defects – mold erosion, rough like misruns and cold shuts. These defects
spots, blowholes etc. are caused due to cold dies, low metal
temperature, dirty metal, lack of venting or
excess lubricant

This is a labor intensive, high unit cost and All metals and alloys can not be cast using
time consuming process this process
Disadvantages: Sand Casting & Die Casting
Sand Casting Die Casting
Moulds with too complex geometries The cost of machines, dies and other
cannot be produced equipment used is high

This process is not suitable for mass This process is not economical for small
production quantity production and heavy castings are
not recommended
 Die Casting : Classifications

In general, castings produced by metallic moulds are classified as

1. Gravity mould castings

2. Pressure applied castings (Pressure die castings)

3. Centrifugal castings

4. Slush castings
 Gravity Mould Casting
• It is referred to as Gravity die casting or Permanent mould casting
• The process makes use of a metallic mould to produce the casting
• Two halves of the die are used to produce the casting
• The die halves are cleaned well first then the dies are preheated
• The dies are covered with a refractory mould coat and then are closed
and clamped
• Molten metal is then poured into the cavity via sprue/pouring cup and
allowed to solidify under gravity or atmospheric pressure
• Metal is then allowed to cool and after solidification, casting is removed
by opening the mould/die halves
 Gravity Mould Casting
• It is referred to as Gravity die casting or Permanent mould casting
• The process makes use of a metallic mould to produce the casting
• Two halves of the die are used to produce the casting
• The die halves are cleaned well first then the dies are preheated
• The dies are covered with a refractory mould coat and then are closed
and clamped
• Molten metal is then poured into the cavity via sprue/pouring cup and
allowed to solidify under gravity or atmospheric pressure
• Metal is then allowed to cool and after solidification, casting is removed
by opening the mould/die halves
 Pressure Die Casting
• In this process a permanent mould into two halves are used to produce
the castings, repeatedly
• External pressure is used to force the molten metal into the mould
cavity
• Thinner castings can be produced as compared to gravity castings
• It can be further classified into High Pressure and Low Pressure Die
Casting
 Pressure Die Casting
• In this process a permanent mould into two halves are used to produce
the castings, repeatedly
• External pressure is used to force the molten metal into the mould
cavity
• Thinner castings can be produced as compared to gravity castings
• It can be further classified into High Pressure and Low Pressure Die
Casting
 Die Casting : High Pressure

• In this process a pressure of 7-500 N/mm2 is applied on the molten metal

during solidification
• Very thin and intricate castings can be produced
• Very high mechanical properties, good surface castings can be produced
• Section thickness <6mm can be easily produced
• Any metal or alloy can be cast
• Very large number of castings can be produced in a single die
 Die Casting : High Pressure

• In this process a pressure of 7-500 N/mm2 is applied on the molten metal

during solidification
• Very thin and intricate castings can be produced
• Very high mechanical properties, good surface castings can be produced
• Section thickness <6mm can be easily produced
• Any metal or alloy can be cast
• Very large number of castings can be produced in a single die
 Die Casting : High Pressure
High pressure die casting can be further classified into :

1. Cold chamber die casting process (CCDP)

In this process molten metal is poured outside the die chamber and
then forced into the die cavity
- There will be a drop in the metal temperature by the time it
reaches the die cavity
- A separate melting unit is used to prepare the molten metal

2. Hot chamber die casting process (HCDP)

In this process molten metal is carried through a unit which is submerged in the
molten metal itself
- Molten metal is forced into the die cavity and hence metal does not loose any
temperature at all
 Die Casting : High Pressure
High pressure die casting can be further classified into :

1. Cold chamber die casting process (CCDP)

In this process molten metal is poured outside the die chamber and
then forced into the die cavity
- There will be a drop in the metal temperature by the time it
reaches the die cavity
- A separate melting unit is used to prepare the molten metal

2. Hot chamber die casting process (HCDP)

In this process molten metal is carried through a unit which is submerged in the
molten metal itself
- Molten metal is forced into the die cavity and hence metal does not loose any
temperature at all
 Die Casting : Low Pressure

• In this process a pressure of approximately 1 N/mm2 is applied on the molten

metal during solidification
• Die halves are closed and molten metal is poured into the mould cavity and
pressure is applied immediately
• After few minutes, the die is opened and the casting is removed
 Die Casting : Low Pressure

• In this process a pressure of approximately 1 N/mm2 is applied on the molten

metal during solidification
• Die halves are closed and molten metal is poured into the mould cavity and
pressure is applied immediately
• After few minutes, the die is opened and the casting is removed
 Centrifugal Casting
• In this process molten metal is introduced into a rotating mould and the
centrifugal force generated will force the metal into the cavity thus shaping
and feeding the casting
• The molten metal solidifies under the influence of centrifugal force
• It is suitable for mass production of cylindrical shaped components

There are various Centrifugal Casting methods :

1. True centrifugal casting

2. Semi centrifugal casting

3. Centrifuge casting
 Centrifugal Casting
True Centrifugal Casting :

• This method is used to produce hollow cylindrical castings of uniform inner

diameter
• The mould is spun vertically or horizontally about its own axis
• Hexagonal, square, round etc. contours on the outside and cylindrical inside
can be easily produced in this casting
• Moulds can be made of metal or dry sand
• A centrifugal force of 50-100g can be attained in this process
• Thickness of the casting is controlled by the amount of liquid metal poured
into the mould
 Centrifugal Casting
True Centrifugal Casting :

• This method is used to produce hollow cylindrical castings of uniform inner

diameter
• The mould is spun vertically or horizontally about its own axis
• Hexagonal, square, round etc. contours on the outside and cylindrical inside
can be easily produced in this casting
• Moulds can be made of metal or dry sand
• A centrifugal force of 50-100g can be attained in this process
• Thickness of the casting is controlled by the amount of liquid metal poured
into the mould
 True Centrifugal Casting
True Centrifugal Casting can be either :

• Vertical Type

• Horizontal Type
 True Centrifugal Casting - Vertical
• Molten metal is poured from the top into the mold which is kept rotating
about its vertical axis. Metal is forced out from the center of rotation and
gets stuck onto the mould walls. Metal solidifies in the form of hollow
cylinder. Rotation is stopped and casting is taken out.
 True Centrifugal Casting – Horizontal
• It is used to produce long pipes. A metal mould is used in general for
casting. The axis of the mould is slightly inclined to the horizontal.
 Semi Centrifugal Casting
• A simple cylindrical pipe casting is produced in true CF method
• Gear blanks, wheels etc. are produced using this technique
• A core is used to form the central cavity in the casting
• CF force is used to force the molten metal to get the shape in the casting
• A speed of 300-500 RPM is employed
• Cope and drag moulds are made in sand and fixed on to the casting
machine
• Core is also assembled
• The riser extended to the top surface acts as pouring basin
• The mould is kept rotating and molten metal is prepared
• Molten metal gets thrown outward forcing it against the mould wall
• Molten metal solidifies and casting shape is formed
• After cooling, casting is taken out
• A fresh mould is kept and the process is repeated
 Semi Centrifugal Casting
• A simple cylindrical pipe casting is produced in true CF method
• Gear blanks, wheels etc. are produced using this technique
• A core is used to form the central cavity in the casting
• CF force is used to force the molten metal to get the shape in the casting
• A speed of 300-500 RPM is employed
• Cope and drag moulds are made in sand and fixed on to the casting
machine
• Core is also assembled
• The riser extended to the top surface acts as pouring basin
• The mould is kept rotating and molten metal is prepared
• Molten metal gets thrown outward forcing it against the mould wall
• Molten metal solidifies and casting shape is formed
• After cooling, casting is taken out
• A fresh mould is kept and the process is repeated
 Semi Centrifugal Casting
• A simple cylindrical pipe casting is produced in true CF method
• Gear blanks, wheels etc. are produced using this technique
• A core is used to form the central cavity in the casting
• CF force is used to force the molten metal to get the shape in the casting
• A speed of 300-500 RPM is employed
• Cope and drag moulds are made in sand and fixed on to the casting
machine
• Core is also assembled
• The riser extended to the top surface acts as pouring basin
• The mould is kept rotating and molten metal is prepared
• Molten metal gets thrown outward forcing it against the mould wall
• Molten metal solidifies and casting shape is formed
• After cooling, casting is taken out
• A fresh mould is kept and the process is repeated
Semi Centrifugal Casting
Semi-centrifugal castings is used to
produce solid castings with hollow cavities
• Hence requires a core

It is used only for symmetrical

shaped objects and the axis of
rotation of the mould is always
vertical.
 Centrifuge Casting
In this type of casting a group of small moulds are
arranged in a circle around the central vertical axis of
the cavity (flask) and the flask cavity is rotated about
the vertical axis – centrifugal casting.

A higher pressure is generated due to centrifugal

force and hence the liquid metal reaches every part
of small moulds and produces more dense castings.

In true and semi-centrifugal casting, the axis of the

mould/cavity coincide with the axis of rotation.
In case of centrifuge casting, these axes do not coincide.
Slush Casting
 Slush Casting
• Castings with external features having aesthetic value are made by this
technique
• Castings will be hollow inside with non-uniform wall thickness
Example : Lamp posts, toys etc.
• Core is not required for this casting process
• Molten metal is poured into the metal mould
• After few seconds the mould is inverted and the molten metal is drained
out into a container
• A thin layer of solidified metal is formed in the mould
• The mould is opened and the thin layered casting is taken out
 Slush Casting
• Castings with external features having aesthetic value are made by this
technique
• Castings will be hollow inside with non-uniform wall thickness
Example : Lamp posts, toys etc.
• Core is not required for this casting process
• Molten metal is poured into the metal mould
• After few seconds the mould is inverted and the molten metal is drained
out into a container
• A thin layer of solidified metal is formed in the mould
• The mould is opened and the thin layered casting is taken out
 Investment Casting
• Investment casting is also known as “lost wax process”
• At first a pattern is made of wax/plastic either by injection molding or
rapid prototyping techniques
• The pattern is then dipped into a slurry of refractory material (mixture of
fine silica and binders, including water, ethyl silicate and acids to form a
coating on the surface of the pattern
• This coating process is repeated several times to increase the thickness of
this coating
• The mould is then air-dried and heated to a temperature of 90 °C -175°C
in an inverted position until entire wax/plastic melts out leaving behind
the hardened and baked refractory material* (which acquires the shape
of the casting to be done)
• Then molten metal is poured into the mould, solidified and cooled, the
baked coating is removed by shaking or breaking it leaving behind the
final casting
• Small similar products can be joined to make one mould – a tree, which
highly increases productivity rate
 Investment Casting
• Investment casting is also known as “lost wax process”
• At first a pattern is made of wax/plastic either by injection molding or
rapid prototyping techniques
• The pattern is then dipped into a slurry of refractory material (mixture of
fine silica and binders, including water, ethyl silicate and acids to form a
coating on the surface of the pattern
• This coating process is repeated several times to increase the thickness of
this coating
• The mould is then air-dried and heated to a temperature of 90 °C -175°C
in an inverted position until entire wax/plastic melts out leaving behind
the hardened and baked refractory material* (which acquires the shape
of the casting to be done)
• Then molten metal is poured into the mould, solidified and cooled, the
baked coating is removed by shaking or breaking it leaving behind the
final casting
• Small similar products can be joined to make one mould – a tree, which
highly increases productivity rate
Investment Casting
Investment Casting
 Induction Furnace

• Introduction

• Advantages

• Construction

• Working Principle
 Induction Furnace
• Induction heating is the process of heating an electrically
conducting object (usually metals) by electromagnetic
induction, through heat generated in the object using eddy
currents. Induction heating is a non-contact form of heating

• Induction heating capacities range from less than 1 Kg to upto

100 Tonnes and are used to melt iron, steel, copper,
aluminium etc.

• Operating frequencies range from utility frequency (50-60 Hz)

to 400 kHz or higher, usually depending on the material being
melted, the capacity (volume) of the furnace and the melting
speed required
 Induction Furnace
Principle of induction heating is mainly based on two important
well known phenomenon :

• Electromagnetic induction : The energy transfer to the

object to be heated occurs by means of electromagnetic
induction. Any electrically conductive material placed in a
variable magnetic field is the site of induced electrical
currents, which is also known as eddy currents and will
eventually lead to joule heating

• Joule heating effect : Joule heating also known as OHMIC

HEATING and RESISTIVE HEATING, is the process by which the
passage of an electric current through a conductor releases
heat
 Induction Furnace
Advantages of Induction Furnace

• It is a clean process

• Less polluting

• Energy efficient

• Well-controllable melting process compared to most other

means of metal melting
 Induction Furnace
Construction of an Induction Furnace
 Induction Furnace
Construction of an Induction Furnace
 Induction Furnace
Working Principle of an Induction Furnace

• An induction furnace operates on a

similar principle to a transformer
• The induction coil acts as primary
coil having many turns and the
charge acts as secondary coil, with
only single turn
• When an alternating current is
applied to the induction coil of a
furnace, a significantly larger
current is induced in the metallic
charge materials
• The resistance to the passage of the • Once the metal is molten, the magnetic field
induced current within the furnace generated creates a stirring action in the
charge causes the charge to heat up bath, producing both homogenization of the
until it eventually melts chemical composition and assimilation of
any additions