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CASTING PROCESS - 1
Assoc Prof Zainal Abidin Ahmad
Universiti Teknologi Malaysia
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Outline
Overview of casting technology
What is casting
Brief history of casting
Advantages & disadvantages of casting
Products made by casting
Casting Classifications
Casting Foundries
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Classification of Manufacturing Processes
Process
Casting
Machining/
Cutting
Forming
Assembly/
J oining
Permanent Mould
Permanent Pattern
Expendable mould &
Pattern
Electro-machining
Mechanical Machining
Sheet
Bulk
Powder
Fusion welding
Solid state welding
Adhesive bonding
Mechanical fastening
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What is Casting?
Process in which molten metal flows by
gravity or other force into a mold where it
solidifies in the shape of the mold cavity
The term casting also applies to the part
made in the process
Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
4. Break-up or open mold and remove casting
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What is Casting?
Melt material
Pour into Mould
and allow to solidify
Break up mould and
remove casting
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CASTING
Referring to
the process
or the product
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Capabilities and Advantages of Casting
Can create complex part geometries
Can create both external and internal shapes
Some casting processes are net shape; others
are near net shape
Can produce very large parts
Some casting methods are suited to mass
production
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Disadvantages of Casting
Different disadvantages for different casting
processes:
Limitations on mechanical properties
Poor dimensional accuracy and surface finish for
some processes; e.g., sand casting
Safety hazards to workers due to hot molten metals
Environmental problems
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Parts Made by Casting
Big parts: engine blocks and heads for
automotive vehicles, wood burning stoves,
machine frames, railway wheels, pipes, church
bells, big statues, and pump housings
Small parts: dental crowns, jewelry, small
statues, and frying pans
All varieties of metals can be cast, ferrous and
nonferrous
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Parts Made by Casting
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Two Categories of Casting Process
1. Expendable mold processes uses an
expendable mold which must be destroyed to
remove casting
Mold materials: sand, plaster, and similar materials,
plus binders
2. Permanent mold processes uses a permanent
mold which can be used many times to produce
many castings
Made of metal (or, less commonly, a ceramic
refractory material
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Casting Processes
Permanent mould
Continuous casting
Gravity die casting
Squeeze casting
Centrifugal casting
Reaction injection
moulding
Injection moulding
Compression moulding
Rotational moulding
Permanent pattern
Sand Casting
Shell moulding
Expendable mould &
pattern
Investment Casting
Ceramic/plaster
mould casting
Full mould
evaporative pattern
casting
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Advantages and Disadvantages
More intricate geometries are possible with
expendable mold processes
Part shapes in permanent mold processes are
limited by the need to open mold
Permanent mold processes are more economic
in high production operations
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