Metal Casting

METAL CASTING

1. History of Casting
2. Why Casting?
3. Basic casting process
4. Basic terms used in casting
5. Steps in casting process
 Introduction

▪ A process based on the property of liquid to take up

the shape of the vessel containing it.
▪ A cavity of desired shape is made, contained in a
mold.
▪ Carried out in a foundry.
 History of Casting
▪ Ancient process, started
5000 years ago.

▪ Jaivana- 50 tons cannon

was built in 17th century
in Jaipur.

▪ Used for making arrows,

coins, knives etc.
World’s largest Cannon in
Jaipur, made by casting
 Why Casting?

1. A job of 5m diameter and 10m length.

2. A job with a hole of 2m diameter, made of very hard
material.
3. Parts of very complicated shapes.
Have you seen any similar process before?
▪ What do we control?
1. Size & shape of cavity
and mold
2. Mixture composition
3. Temperature
4. Cooling time
5. Carefully remove it
 Requirement for Casting?

1. Cavity of desired shape- Mold

2. Molten metal
3. Proper channel to fill the molten metal
Basic Casting Process
 Basic terms used in Casting
1. Pattern: Replica of the desired part
2. Mold- Container with a cavity within. Divided in two
halves: Cope and Drag.
3. Gating system- Network of channels that deliver
molten metal to the cavity.
 Basic steps in Casting

1. Pattern making
2. Mold making
3. Melting of metal and pouring
4. Cooling and solidification of metal
5. Cleaning of casting and inspection
 Pattern
▪ Replica of the desired product
▪ Has somehow different dimensions than the actual part to
be manufactured
▪ Used to form the mold cavity

1. Materials used
2. Types of patterns
3. Pattern Allowances
 Pattern Materials

▪ Requirements:
1. Easily shaped, worked, machined and joined
2. Resistant to wear and corrosion
3. Resistant to chemical action
4. Dimensionally stable
5. Easily available and economical
 Pattern Materials
1. Wood:
⮚ Easy availability, low weight and low cost

⮚ Can be easily shaped

⮚ More than 90% castings use wood patterns

⮚ Absorbs moisture. So, distortions and dimensional changes occur

⮚ Relatively lower life, hence suitable for small quantity production

 Pattern Materials
2. Metal:
⮚Used for large quantity production and for closer dimensional
tolerances

⮚Longer life

⮚Aluminum is mostly used.

⮚Other metals: cast iron, brass etc.
 Pattern Materials
3. Plastic:
⮚Low weight, easier formability, smooth surfaces and durability

⮚Do not absorb moisture. So, dimensionally stable

⮚Corrosion resistance
 Pattern Materials
4. Polystyrene:
⮚Changes to gaseous state on heating
⮚Disposable Patterns. Hence, suitable for single casting.
⮚When molten metal is poured into cavity, polystyrene transforms
to gaseous state.
⮚Used mostly for small and complicated shaped castings.
 Pattern Types

1.Single piece pattern:

▪ Used for simple shaped & large
castings.
▪ Pattern and cavity produced by it
are completely in the lower flask (i.e.
drag)
▪ Causes difficulty in making the
mold.
 Pattern Types

2.Split pattern:
▪ Split pattern models the part as
two separate pieces that meet along
the parting line of the mould
▪ Two parts are aligned by Dowel pin.
 Pattern Types

3.Loose Piece pattern

1. As pre The name Pattern Contain One or more than one loose piece
2. Loose piece is used to make removal of pattern easy from mould box
3. loose pieces are attached to main body with the help of dowel pins or
wire
4. First main pattern is drawn and then carefully loose pieces
5. Moulding with this pattern is expensive and require more skill
 Pattern Types
4. Match-plate pattern:
▪ Similar to a split pattern, except that each half of the pattern is attached to
opposite sides of a single plate.
▪ Match plate confirms the parting line
▪ Ensures proper alignment of the mould cavities in the cope and drag and the
runner system can be included on the match plate.
▪ Used for larger production quantities.
▪ Ic Engines piston rings
 Pattern Types

4. Cope-Drag pattern:
▪ It is similar to split pattern
▪ Each half of the pattern is attached to a separate plate and the mould halves
are made independently.
▪ .Pattern is made in two halves and split along parting line
▪ These two halves are known as cope and drag
▪ There moulding done independently
▪ After moulding they are assembled to form complete mould box
▪ Often desirable for larger castings
 Pattern Types
5. Gated pattern:
▪ In this patters of gate and riser or runner are permanently attached to
regular pattern
▪ They are used to manufacture multiple casting in on time
▪ Each pattern is connected with common runner .
▪ Suitable for pouring small castings and for mass production
▪ It save labour and time
 Pattern Allowances

1. Shrinkage or contraction allowance

2. Draft or taper allowance

3. Machining or finish allowance

4. Distortion or camber allowance

5. Rapping allowance
 Pattern Allowances

▪ Shrinkage Allowance:

⮚ Liquid Shrinkage
⮚ Solid Shrinkage
Pattern Allowances
 Pattern Allowances

▪ Shrinkage Allowance:
⮚ Shrinkage means contraction of metal on solidification
⮚ All metals shrink after solidification. (Except grey cast iron that
expands on solidification).
⮚ It is expressed in mm/m.
⮚ Shrinkage allowance Differs from material to material.
⮚ Positive type of allowance.
▪ Draft / Taper Allowance:

Pattern Allowances

▪ Taper provided by the pattern maker on all vertical surfaces of

the pattern so that it can be removed from the sand without
tearing away the sides of the sand mould.
▪ Inner details of the pattern require higher draft than outer
surfaces.
▪ commonly applied draught allowance is 1°to 3°
▪ due to draught allowance pattern can easily removed from mould
box
 Pattern Allowances
▪ Draft / Taper Allowance:

▪ The amount of draft depends upon-

1. The length of the vertical side of the pattern to be extracted;

2. The intricacy of the pattern;

3. The method of moulding

4. Pattern material.
Pattern Allowances
 Pattern Allowances

▪ Machining / Finishing Allowance:

▪ The finish and accuracy in sand casting is generally poor.
▪ Extra material provided on the casting to enable their machining
or finishing to the required size, accuracy and surface finish.
▪ So it is Added in pattern dimensions.
▪ allowance is provided only in machining area
▪ Amount of machining allowance depends upon:
1. Method of moulding and casting used
2. Size and shape of casting
3. Casting orientation
4. Metal used in casting
5. Degree of accuracy and finish required
Pattern Allowances
 Pattern Allowances

▪ Distortion / Camber Allowance:

▪ Due to their typical shapes (U,V,T,L shapes) , castings get
distorted during solidification.
▪ Distortion is observed in irregular castings so that it shrink in
uneven manner
▪ Distortions are caused by internal stresses which are generated
on account of unequal cooling of different sections of casting.
▪ To avoid this distortion allowance is provided
▪ It varies from 2 to 20 mm
 Pattern Allowances

▪ Rapping / shake Allowance:

▪ Before the withdrawal from the sand mould, the pattern is
rapped all around the vertical faces to enlarge the mould cavity
slightly, which facilitate its removal.
▪ When pattern is rapped, mould cavity is enlarged.
▪ To account for this increase, pattern size is reduced.
▪ This allowance is important in large-sized castings and precision
castings.
▪ Amount of rapping allowance depends upon:
1. Extent of rapping
2. Degree of compaction of sand
3. Size of mould
4. Sand type
 Tools

■ It include carpenter tools and some special tool

1. Contraction scale- It is used to measure pattern dimensions
include various allowances.It is metallic scale of 300 or 500 mm
length
2. Combination set- It generally used for pattern making.It is used
to measure angles,pependicularity,locate centre on cylindrical
job.
3. Callipers- They are of internal or external type.Generally
used to measure internal or external diameters of patterns.
 Tools

1. Ratchet brace- This is used to drill holes in horizontal and

vertical plane.
2. Wheel brace- It produce only small holes. It can drill small
holes accurately nd quickly.
3. Back saw and plane- They are used for Curtin and parting
operations.
 COLOUR CODING FOR PATTERN
● Pattern are coloured by using shellac paints.
● Colours gives protection and identifies the features of patterns.
● colour scheme is given as bellow

Colour Indication
Black Unfinished surface
on casting
Red Finished surface on
casting
Yellow Core prints
Black Parting surface
Red/yellow strips Seats for loose
 Moulding
▪ The term moulding process refers to the method of making the
mould and the materials used.
▪ Moulding processes have certain features in common-
1. The use of pattern.
2. Some type of aggregate mixture comprising a refractory and binders.
3. A means of forming the aggregate mixture around the pattern.
4. Hardening of aggregate or developing its bond while in contact with the
pattern.
5. Withdrawal of the pattern from the mould.
6. Assembly of the mould and core pieces to make a complete mould, metal
then being poured into the mould.
 Moulding
▪ Classification of Moulding Processes:
 Types of Moulding Sands
▪ Green Sand:
⮚ Natural sand prepared as a mixture of silica sand with 18-30 % clay and 6-
8 % moisture.
⮚ Fine, soft, light and porous.
⮚ The name ‘Green sand’ employs for damped i.e. it contains moisture and
the mould made of this sand is used immediately to pour the molten metal.
⮚ Easily available and has low cost.
 Types of Moulding Sands
▪ Dry Sand:
⮚ Green sand that has been dried or baked in between 250° to 550° in
suitable oven after the making mould and cores, is called dry sand.
⮚ More strength, rigidity and thermal stability.
⮚ Suitable for larger castings.
 Types of Moulding Sands
▪ Parting Sand:
⮚ It is used to keep away the green sand from sticking to the pattern and to allow the
sand on the parting surface of the flasks to separate without clinging.
⮚ It is free from clay and is dry.
⮚ It is washed and non sticky sand
 Types of Moulding Sands
▪ Core Sand:
⮚ Used to make core.
⮚ Should be stronger than the moulding sand.
⮚ It is made by mixing core linseed oil with silica sand,
⮚ It is also called as soil sand
 Backing sand
● It usually contains burnt facing sand, moulding sand and clay.
● It is old and repeatedly used sand and used for baking facing sand
● It is filled behind the facing sand in the mould box or flask.
 Facing sand
● It is mixture of floor sand and new moulding sand with suitable binder and moisture.
● It is used next to the parting surface and comes in contact with molten metal when poured into the
mould
● It is used around a pattern to cover it upto 2.5 to 5cm
 Types of cores
1. Horizontal core.
2. vertical core.
3. Balanced core.
4. Cover core.
5. Drop core.
 Types of cores

1. Horizontal core.
• As par the name it kept horizontally in the mould box.
• Its position is along parting line.
• It is commonly used in foundary.
 Types of cores
2.Vertical core.
• Its is placed vertical in mould box.
• It occupies cope and drag.
• both the ends are rest in the core seat provided in the cope and drag.
• both the ends are tapered and maximum portion is located in drag.
 Types of cores
3.Balanced core.
• only blind holes or holes which are open at one side are produced by balanced casting.
• Balanced core has only one core print to maintain alignment of core
• core print and portion of core outside the mould cavity is kept slightly larger and heavier
 Cover core
● It is supported on drag and completely moulded in drag
● Core serve as cover for the mould
 Drop core
● It is used to produce holes in casting above or bellow the parting line.
● taper is provided to side of core for way placement
Elements of gating system
 Types of moulding
1. Bench moulding
• In this method small mould are made upon bench
• It is used to manufactured the green sand and dry sand mould.
• loose piece patterns are used for moulding.
• Ramming is done manually.
• Slow process and requires labours.
• it is having types
1. Two box moulding.
2. Three box moulding.
3. stacked moulding.
 Types of Casting Methods
1. Centrifugal casting.
• In this process mould is poured and allowed to solidify during revolving.
• Due to rotation of mould the poured metal is subjected to centrifugal force.
• Centrifugal force is allowed molten metal to flow in the mould cavity.
• Dence metal is deposited on periphery of mould and start sophistication.
• Lighter slag, oxides, inclusions are get separated and moves towards centre.
 Centrifugal casting
• There is no use of gates runner and riser.
• The axis of rotation may be horizontal or vertical.
• Applications
• Pipes , cylinder liners, bearings, bushes, gears fly wheels, gun barrels etc.
 Shell moulding
• This process is used for smooth surface finish
• It consist of dump box which is partially filled with silica and thermoelectric resin.
• Then dump box is sealed with metallic pattern which is preheated about 250°c.
• When dump box is inverted mixture is get melted and forms the shell on pattern plate.
• Shell thickness varies from 5mm to 8mm.
• These two shells joint togather to form complete mould.
•
 Shell moulding
● Applications.
• small pulleys ,motor housing, fan blades, cylinders, cylinder heads, break drums.
 Investment casting

• It is also known as lost wax casting precision casting.

• This method is used for manufacturing jewellry,dental goods.
• It involves following steps.
1. Making of wax pattern sometimes mercury or plastic may be used.
2. provide wax made gates, runners, riser to the pattern.
3. Complete wax pattern put in box and filled with liquid mould material.
4. liquid around wax pattern solidifies and form mould
5. Then mould is heated to 150°to 800°c to remove wax
 Investment casting
● Applications.
• surgical instruments.
• vanes and blades for gas turbine.
• costume jewellery.
• valve bodies.
• Reciprocating slides for cloth cutting machine.
 Casting defects
Following are the casting defects arises during faulty processes in casting.
1. Blow holes.
2. Pin holes.
3. Shift.
4. Short runs.
5. Hot tears.
6. cold shuts.
Thank You