TOPIC 4

CONTEMPORARY CASTING
PROCESSES
Introduction
• Sand-mold
Traditional
castings
casting
• Dry-sand casting

• Die casting
Contempo • Permanent
rary / Non-
traditional mold casting
casting • Centrifugal
casting
Introduction

A casting depends on quantity, metal to be cast & intricacy of the

part
Introduction
Permanent molds

whenever
cost saving
Permanent the size of
for big
molds offer the casting
production
is not large

Metal molds

Permanent molds - constructed of metals

- capable withstanding high temperatures
- High cost : recommended when many
castings are produced
Die Casting
Die Casting

• most popular of permanent –

mold process
• molten metal is forced by
pressure into a mold known
as a die
• metal solidifies at a pressure
from 0.6 to 275 Mpa
• casting conforms to the die
cavity in shape and surface
finish
• normally the pressure is
from 10.3 to 14 Mpa
Die Casting
- Dies for hot and cold-chamber machine are
similar in construction.
- Dies are made in to halves to allow Casting
removal.
- Metal enters the stationary half when the die is
closed.
- When the die opens ejector-pins for the casting to
fall from the die
Die Casting

- Die life depends on the metal cast ( Range from

10,000 filling for brass to several million for zinc).

- Vents should be considered to allow the gases to escape

- Dies are provided with water channels to cool the die

after injection to metal (For rapid production)
Die Casting
Die Casting
2 methods of die casting can be used depending on the type of metal being cast :

Hot Chamber Cold Chamber

- melting pot is included - separated melting

within the machine. furnace
- the injection cylinder is - Metal injected into
immersed in the molten cylinder by mechanical
metal at all times means or hand

-The injection cylinder is -Hydraulic pressure then

actuated by air or forces the metal to die
hydraulic pressure -The process is rapid
- then force the metal into because the die and
dies to complete casting core are permanent

Remark : The difference - It is determined by the location of the melting pot

 Die Casting
Hot-Chamber Die Casting
•Low melting alloys of zinc, tin and lead are the materials
cast in hot-chamber machines.
•Metal is forced into the mold and pressure is maintained
during solidification either by plunger or compressed air.
•The plunger type machine is
shown is hydraulically
operated for both plunger &
both mechanism closing &
opening the die.
 Die Casting
Hot-Chamber Die Casting
Die Casting
Cold Chamber Die casting
•These metals are not melted in a self contained pot,
because the life of the pot would be very short.
•Normal procedure heats the metal in an auxiliary furnace
and ladles it to the plunger cavity next to the dies.
•It is then forced into the dies under hydraulic pressure.
•These machines are built to withstand the heavy
pressures exerted on the metal as it is forced into the dies.
•Generally there are types-a) Plunger in vertical position
b) Horizontal position
•These machines are fully hydraulic and semiautomatic.
Die Casting
Cold Chamber Die casting.
Die Casting
HOT Chamber Die casting. Cold Chamber Die casting.
Lower pressure permanent moulds
Permanent Mold Casting

No pressure is used (only gravity). It

Is used for ferrous and non-ferrous
metals.
 Permanent Mold Casting

The die is closed using a cylinder and

the molten metal is simply poured into
the mould cavity by hand or mechani-
cal means. The metal fills the cavity
because of the pressure created by
the head of the metal poured (no plu-
nger) is used to keep the casting under
pressure).
 Permanent Mold Casting
Casting cycle:

Pouring, cooling, ejecting, and setting the cores

Advantage: Good finish and surface of the castings,

capability of maintaining small tolerances.

Disadvantage: Good High cost of equipment

and dies.
Centrifugal Mold Casting
Centrifugal Casting
•The process of rotating a mold while metal solidifies and
utilize centrifugal force to position the metal in mold.
•Symmetrical shape of casting can be made.
•Centrifugal casting is
often economical than
other methods.
•Cores are cylindrical
shapes, risers & feed
heads are eliminated.
Centrifugal Mold Casting
 Centrifugal Mold Casting

1- True Centrifugal Casting

This method is used to produce pipes,
bars, cylinders and other symmetric
objects. The mould rotates about its
horizontal or vertical axis. THREE or
TWO types:
 Centrifugal Mold Casting
a- Using a massive thick metal mould with a
thick refractory coating. As a result of this
design, the solidification will proceed from
the mould wall toward the casting centre.

b- Using a thick, highly insulated sand interface

between the mould wall and the casting. In this
case, the solidification will start from the casting
center and from the wall at the same time.
 Centrifugal Mold Casting
Finding the centrifugal force CF:

The centrifugal force is created by the

mould rotation about its axis. If too low
A centrifugal force is applied, the
metal will slide, slip or rain.
2
mv
CF =
r
Centrifugal Mold Casting

Horizontal
Centrifugal Mold Casting
 Centrifugal Mold Casting

2- Semicentrifugal Casting

The mould is completely full of metal. The centre of

the casting is solid but with less density then it is in
the surface of the casting. Usually, the centre of the
casting will be removed using machining processes.

Advantage: Good dense surface of

the metal, especially near the surface.
Centrifugal Mold Casting
Centrifugal Mold Casting
3- Centrifuging
Several cavities are located around the
mould axis. As the mould is rotated,
the CF encourages the metal to fill
the cavities through radial gates.

Advantage: Not limited to symmetrical

objects.
Centrifugal Mold Casting
Precision or investment Casting:
This process is used to cast unmachi-
nable alloys and radioactive metals
(Poor machinability).
Advantage:
1-Intricate and smooth casting.
2-Good for unmachinable metals and it
Can replace die-casting.
 Cont… Precision or investment Casting:

Disadvantage:
1- Very expensive.
2- Limited to small parts.

3- some difficulties when cores are

used .
Type of Precision or investment Casting

1-“Lost Wax” precision casting process.

A wax pattern is used to form a cavity
In the mould. The Wax pattern is cove-
red with plaster investment. When this
plaster becomes hard the plaster
mould will be heated. As a result, the
Wax pattern will melt away from the
mould leaving a cavity having all the
details of the Wax pattern.
Schematic illustration of investment casting

1. WAX INJECTION : Wax replicas of the desired

castings are produced by injection molding.
These replicas are called patterns.
Schematic illustration of investment casting

2. ASSEMBLY : The patterns are attached to a

central wax stick, called a sprue, to form a
casting cluster or assembly.
Schematic illustration of investment casting

3. SHELL BUILDING : The shell is built by

immersing the assembly in a liquid ceramic slurry
and then into a bed of extremely fine sand. Up to
eight layers may be applied in this manner.
Schematic illustration of investment casting

4. DEWAX : Once the ceramic is dry, the wax is

melted out, creating a negative impression of the
assembly within the shell.
5. CONVENTIONAL CASTING: In the conventional
process, the shell is filled with molten metal by
gravity pouring. As the metal cools, the parts and gates,
sprue and pouring cup become one solid casting.
6. KNOCKOUT: When the metal has cooled and
solidified, the ceramic shell is broken off by
vibration or water blasting.
7. CUT OFF: The parts are cut away from the central
sprue using a high speed friction saw.
8. FINISHED CASTINGS: After minor finishing
operations, the metal castings--identical to the
original wax patterns--are ready for shipment to the
customer.
 Cont… Type of Precision or investment Casting

2-Plaster Mould Casting.

1- Mold is made of plaster
2- Mixed with water and additives and
poured over a pattern
3- After plaster sets, pattern is removed
and the mold is dried at 120 C
4- Have low Permeability – gases can not
escape
5- Patterns are made of:
 Cont… Type of Precision or investment Casting

-Al alloys,
-Thermosetting plastics
-Brass or Zinc alloys
6-Have fine details and good surface
finish
7-Form of precision casting
Plaster moulds are also not permanent
because they are destroyed when the
casting is removed.
Cont… Type of Precision or investment Casting
Continuous Castings

Continuous casting process consists

of continuously poring the molten metal
into a mould that has the capability for
rapidly chilling the metal to the point
of solidification and then withdrawing
It from mould.
Continuous casting
Continuous casting and hot rolling plant
Asarco process
The mould is built in the furnace. The
molten metal is fed by gravity into the
mould from furnace. At the mould exit,
the metal solidifies and it is withdrawn
by rolls. The exit consists of a graphite
die that forms the final shape of the
withdrawn product. The graphite die is
build in a cooling jacket, which uses
water to cool the product at the mould
exit. The products: Bars, Rods.