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Casting Processes
Summary
Green Sand Casting
Process
Sand, bonded with clay and water packed around
a wood or metal pattern
Pattern is removed and molten metal poured
On metal solidification, mold is broken & casting
removed
Advantages
Almost no size, shape, weight limitation
Low cost, Any metal can be cast.
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Green Sand Casting
Limitations
Tolerances and surface finish are poorer than other
casting processes
Machining is often required
Slow production rate
Common Metals
Cast Iron, Steel, Aluminiumalloys, copper, Ni
Size Limit: 30g to 3000 kg
Thickness Limit: 0.25 cm any maximum
Draft Allowance: 1-3 deg
Surface Finish: 2.5 25 microns
Shell Mould Casting
Process
Sand coated with a thermosetting plastic resin is
dropped on to a heated metal pattern which cures
the resin
The shell segments striped from pattern and
assembled
After pouring molten metal, Shell broken away
Advantages
Faster production rate
High dimensional accuracy with smooth surface
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Shell Mould Casting
Limitations
Requires expensive metal pattern
Thermosetting resin adds to cost
Limited part size
Common Metals
Cast Iron, Aluminiumalloys, copper
Size Limit: 30g to 10 kg
Thickness Limit: 0.15-0.6 (min)
Draft Allowance: 0.25 0.5 deg
Surface Finish: 0.3 4.0 microns
Investment Casting
Process
A refractory slurry is formed around a wax or plastic pattern
and allowed to harden.
Pattern is melted out and mold is baked
Molten metal poured and mold broken away from the
casting.
Advantages
Excellent Surface finish
High dimensional accuracy
No parting line & flash problems
Any intricate shape
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Investment Casting
Limitations
Costly patterns and moulds
High labour cost
Limited Size
Common Metals
Steel, Aluminiumalloys, copper, precious metals
Size Limit: 3g to 5 kg
Thickness Limit: 0.06 cm
Draft Allowance: Zero
Surface Finish: 1.3 4.0 microns
Die Casting
Process
Molten metal injected into closed metal dies under
pressure (10-175 MPa)
Pressure maintained during solidification
Dies separated to eject casting
Cores must be simple and retractable
Advantages
Extremely smooth surface
Excellent dimensional accuracy
Rapid production rate
Good product tensile strength
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Die Casting
Limitations
High initial die cost
Limited to high fluidity non-ferrous metals
Limited part size
Porosity may be problem
Common Metals
Aluminiumalloys, Zinc, Magnesium, Cu & Tin alloys
Size Limit: 30g to 7 kg
Thickness Limit: 0.75 mm
Draft Allowance: 2 deg
Surface Finish: 1 2.5 microns
Centrifugal Casting
Process
Molten metal is introduced into a rotating sand,
metal, or graphite mold and held against the mold
wall by centrifugal force until it solidifies.
Advantages
Produce wide range of cylindrical parts
Good dimensional accuracy
Good soundness and cleanliness
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Centrifugal Casting
Limitations
Shape is limited
Expensive spinning equipment
Common Metals
Iron, Steel, Aluminiumalloys, Cu, and Ni
Size Limit: upto 3m dia and 15m length
Thickness Limit: 2.5 - 125 mm
Draft Allowance: 10 mm/m
Surface Finish: 2.5 12.5 microns