Fundamentals of Casting

Casting, one of the oldest manufacturing processes, dates back to 4000 B.C. when copper arrowheads were made. Casting processes basically involve the introduction of a molten metal into a mold cavity, where upon solidification, the metal takes on the shape of the mold cavity. Simple and complicated shapes can be made from any metal that can be melted. Example of cast parts: frames, structural parts, machine components, engine blocks, valves, pipes, statues, ornamental artifacts.. Casting sizes range form few mm (teeth of a zipper) to 10 m (propellers of ocean liners).
Ken Youssefi Mechanical and Areospace Engineering Dept. 1

Casting Processes
Preparing a mold cavity of the desired shape with proper allowance for shrinkage. Melting the metal with acceptable quality and temp. Pouring the metal into the cavity and providing means for the escape of air or gases. Solidification process, must be properly designed and controlled to avoid defects. Mold removal. Finishing, cleaning and inspection operations.
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Sand Casting Terminology

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Sand Casting Process

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Solidification Time

Solidification time = C (volume/surface area)2 Where C is a constant that depends on mold material and thickness, metal characteristics and temperature.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Solidification Time
Sphere, cube and a cylinder with the same volume

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Casting Defects
Hot tearing hot tearing, cracking, occurs if casting is restrained from shrinking, during solidification.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Casting Defects
These defects can be eliminated by proper mold preparation, casting design and pouring process.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Casting Defects
Hot spots thick sections cool slower than other sections causing abnormal shrinkage. Defects such as voids, cracks and porosity are created.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

Casting Defects and Design Consideration

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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Design Consideration

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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Die Casting
Hot chamber, low-melting alloys; tin, zinc, lead. Cold chamber, high-melting alloys; aluminum, copper. Higher pressure needed

High production rates, good strength, good dimensional accuracy and surface finish, and good quality parts.
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Centrifugal Casting
True centrifugal casting

Centrifuging

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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Squeeze Casting

Squeeze cast parts have good mechanical properties, good dimensional accuracy, fine microstructure, good surface finish.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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Precision Casting
Plaster Molding
Plaster of Paris (gypsum) is used as the mold material, other components are added to improve the strength and reduce the setting time. The pattern is dried at 400 oF and the two halves are assembled and molten metal is poured into the cavity. The process produces fine detail with good dimensional accuracy and surface finish. Used to cast aluminum, zinc and copper-based alloys (lowmelting temp.)

Ceramic Molding
Similar to plaster molding, except it uses ceramic as a mold which is suitable for high temp. applications. Mixture of zircon (ZrSiO4), aluminum oxide (Al2O3), silica (SiO2) and other bounding agents.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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Fabrication of Plastics
Injection Molding

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Mechanical and Areospace Engineering Dept.

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Fabrication of Plastics
Hot-Compression Molding Vacuum Forming

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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Design Considerations
Wall thickness should be kept uniform if possible. Non uniform wall thickness could lead to warpage and dimensional variations. Minimum recommended; .025 in or .65 mm, up to .125 for large parts. Round interior and exterior corners to .01-.015 in radius (min.), prevents an edge from chipping.

Ken Youssefi

Mechanical and Areospace Engineering Dept.

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