​​Mechanical Engineering Department

Metal Casting
(Lecture 1)

Dr. Mohammed Gamil

 Casting Methods
1. Centrifugal Casting
2. Shell casting
3. Investment Casting (Lost wax casting)
4. Die Casting
5. Continuous casting
6. Properzi Casting Method
7. Hazelett Casting Method
8. Semicontinuous casting
9. Sand casting
 1. Centrifugal Casting
A family of casting processes in which the mold is
rotated at high speed so centrifugal force
distributes molten metal to outer regions of die
cavity
 The group includes:
A. True centrifugal casting
1. Horizontal
2. Vertical
B. Semicentrifugal casting

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 (A) Centrifugal Casting
Molten metal is poured into a rotating mold to
produce a tubular part
 Rotational axes can be either horizontal or vertical
 Parts: pipes, tubes, bushings, and rings
 Outside shape of casting can be round, octagonal,
hexagonal, etc , but inside shape is (theoretically)
perfectly round, due to radially symmetric forces
 (A) Centrifugal Casting

1. Horizontal

2. Vertical
 (B) Semicentrifugal Casting
Centrifugal force is used to produce solid castings
rather than tubular parts
 Molds are designed with risers at center to supply
feed metal
 Density of metal in final casting is greater in outer
sections than at center of rotation
(B) Semicentrifugal Casting

Examples: wheels and pulleys

 Other Expendable Mold Processes

2. Shell Molding
Casting process in which the cavity (& gating
system) is a thin shell of sand held together by
thermosetting resin binder

part

Steps in shell‑molding: (1) a match‑plate or cope‑and‑drag

metal pattern is heated and placed over a box containing
sand mixed with thermosetting resin.
 Other Expendable Mold Processes

Shell Molding
Steps in shell‑molding: (2) box is inverted so that sand and
resin fall onto the hot pattern, causing a layer of the
mixture to partially cure on the surface to form a hard
shell; (3) box is repositioned so that loose uncured
particles drop away;

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 Other Expendable Mold Processes

Shell Molding
Steps in shell‑molding: (4) sand shell is heated in oven for
several minutes to complete curing; (5) shell mold is
stripped from the pattern;

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 Shell Molding

Steps in shell‑molding: (6) two halves of the shell mold are

assembled, supported by sand or metal shot in a box, and pouring
is accomplished; (7) the finished casting with sprue removed.

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Shell Molding
 Other Expendable Mold Processes

Advantages and Disadvantages

 Advantages of shell molding:
 Smoother cavity surface permits easier flow of
molten metal and better surface finish
 Good dimensional accuracy - machining often
not required
 Mold collapsibility minimizes cracks in casting
 Can be mechanized for mass production
 Disadvantages:
 More expensive metal pattern
 Difficult to justify for small quantities

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 3. Investment Casting

Steps in investment casting: (1) wax patterns are produced, (2)

several patterns are attached to a sprue to form a pattern tree
 Investment Casting

Steps in investment casting: (3) the pattern tree is coated with a thin
layer of refractory material, (4) the full mold is formed by covering
the coated tree with sufficient refractory material to make it rigid
 Investment Casting

Steps in investment casting: (5) the mold is held in an inverted position

and heated to melt the wax and permit it to drip out of the cavity, (6)
the mold is preheated to a high temperature, the molten metal is
poured, and it solidifies
 Investment Casting

Steps in investment casting: (7) the mold is broken away

from the finished casting and the parts are separated
from the sprue
Advantages and Disadvantages
 Advantages of investment casting:
 Parts of great complexity and intricacy can
be cast
 Close dimensional control and good surface
finish
 Wax can usually be recovered for reuse
 Additional machining is not normally
required ‑ this is a net shape process
 Disadvantages
 Many processing steps are required
 Relatively expensive process
 4. 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
 Molds in this casting operation are called
dies; hence the name die casting
 Use of high pressure (7-35MPa) to force metal
into die cavity is what distinguishes this from
other permanent mold processes
 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

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 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
 Injection pressure: 7-35MPa
 Applications limited to low melting‑point
metals that do not chemically attack
plunger and other mechanical components

 Casting metals: zinc, tin, lead, and

magnesium
 Permanent Mold Processes

Hot-Chamber Die Casting

Cycle in hot‑chamber casting: (1) with die closed and plunger

withdrawn, molten metal flows into the chamber

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 Permanent Mold Processes

Hot-Chamber Die Casting

Because the die material does

not have natural permeability
(like sand has), vent holes at
die cavity needs to be made
Cycle in hot‑chamber casting: (2) plunger forces metal in
chamber to flow into die, maintaining pressure during
cooling and solidification.

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 Permanent Mold Processes

Cold‑Chamber Die Casting

Molten metal is poured into unheated chamber from
external melting container, and a piston injects
metal under high pressure (14-140MPa) into die
cavity
 High production but not usually as fast as
hot‑chamber machines because of pouring step
 Casting metals: aluminum, brass, and magnesium
alloys
 Advantage of cold chamber is that high melting
point metals can be casted: Why???

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 Permanent Mold Processes

Cold‑Chamber Die Casting

Cycle in cold‑chamber casting: (1) with die closed and ram

withdrawn, molten metal is poured into the chamber

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 Permanent Mold Processes

Cold‑Chamber Die Casting

Cycle in cold‑chamber casting: (2) ram forces metal to flow

into die, maintaining pressure during cooling and
solidification.

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 Permanent Mold Processes

Molds for Die Casting

 Usually made of tool steel, mold steel, or
maraging steel
 Tungsten and molybdenum (good refractory
qualities) are used to make die for casting steel
and cast iron
 Ejector pins are required to remove part from
die when it opens
 Lubricants must be sprayed into cavities to
prevent sticking

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 Advantages and Limitations
 Advantages of die casting:
 Economical for large production quantities
 Good accuracy (±0.076mm)and surface finish
 Thin sections are possible
 Rapid cooling provides small grain size and good
strength to casting
 Disadvantages:
 Generally limited to metals with low metal points
 Part geometry must allow removal from die, so
very complex parts can not be casted
 Flash and metal in vent holes need to be cleaned
after ejection of part
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5. Continuous casting
 ‫‪6. Properzi Method‬‬

‫إح دى ط رق الس باكه‬

‫المس تمرة وس ميت‬
‫بهذا اإلسم نسبه للعالم‬
‫اإليطالى بروبرزى‬
‫تس تخدم ط ارة من‬
‫النح اس او س بيكه من‬
‫النح اس على س طحها‬
‫الخ ارجى مج رى على‬
‫اع‬ ‫كل القط‬ ‫ش‬
7. Hazelett Method
7. Hazelett Method
8. Semi Continuous Casting