15/7/2014

Diploma in Mechanical Engineering (Material)

JF 302 MATERIAL TECHNOLOGY 1

www.pis.edu.my

CLO 2 : Synthesis course knowledge into an effective

course assignment and present technical findings
both orally and in writing.

Week 7

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cold work

Understand cold work

CASTING
PROCESS

Understand hot work

Describe the casting process
Describe the heat treatment of steels

peneraju ilmu sejagat

cold work

CASTING
PROCESS

hot work

casting process

casting process

Heat treatment of steels

Principle of Operation:
Metal or alloy is heated above its melting point and
pouring the molten metal/alloy in cavity
approximately of same shape and size as the
machine part.
After the molten metal/alloy cools and solidifies, it
acquires the shape and size of the cavity and
resembles the finished product required.

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Heat treatment of steels

Purposes of casting process:

A large number of metal components in designs we
use every day are made by casting. The reasons
for this include:
a. Casting can produce very complex geometry
parts with internal cavities and hallow sections
b. It can be used to make small to very large size
of parts
c. It is economical, with vey little wastage. The
extra metal in each casting is re-melted and reused
d. Cast metal is isotropic. It has the same
physical/ mechanical properties along any
direction.

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hot work

cold work

CASTING
PROCESS

hot work

casting process

Heat treatment of steels

Types of casting processes:

a. Sand casting
b. Shell moulding
c. Investment casting, etc.

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15/7/2014

cold work

SAND
CASTING

hot work

casting process

Heat treatment of steels

Principle of Operation:
It is a metal casting process characterized by using
sand as the mould material.
There are six steps in this process:
i. place a pattern in sand to create a mould
ii. incorporate the pattern and sand in a gating
system
iii. remove the pattern
iv. fill the mould cavity with molten metal
v. allow the metal to cool
vi. break away the sand mould and remove the
casting

cold work

SAND
CASTING

hot work

casting process

Heat treatment of steels

Think critically 3.4

cold work

casting process

Advantages:
a. low capital investment
b. use of sand cores allows complex shapes to be cast
c. small to large size of components can be produced
d. Less wastage as the extra metal can be re-used

hot work

casting process

Heat treatment of steels

What are the extra metals to be cut

off from final product of casting ?

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hot work

Heat treatment of steels

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What are the extra metals to be cut

off from final product of casting ?

cold work

casting process

Disadvantages:
a. high labour intensive and time consuming
b. sand mould leaves bad surface finish, due to sand
indentation and oxidizing medium, which often requires
further processing
c. not suitable for mass production, often used to produce
few number of products compared with other casting
processes which produce thousands and millions
d. bad dimensional accuracy

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cold work

hot work

Think critically 3.4

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Heat treatment of steels

SHELL
MOULDING

cold work

hot work

casting process

Heat treatment of steels

SHELL
MOULDING

Principle of Operation:
1. The 2-piece pattern is made of metal (e.g.
aluminium or steel), it is heated to between
175C-370C, and coated with a lubricant, e.g.
silicone spray.
2. Pattern and dump box are rotated.

Principle of Operation:
3. Each heated half-pattern is covered with a
mixture of sand and a thermosetting resin/epoxy
binder. The binder glues a layer of sand to the
pattern, forming a shell.
4. The assembly is baked to cure.

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15/7/2014

cold work

hot work

casting process

Heat treatment of steels

SHELL
MOULDING

cold work

hot work

SHELL
MOULDING

Disadvantages:
a. more expensive metal pattern
b. difficult to justify for small quantities

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hot work

casting process

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Heat treatment of steels

cold work

hot work

INVESTMENT
CASTING

INVESTMENT
CASTING

Principle of Operation:

Principle of Operation:

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cold work

hot work

casting process

casting process

Heat treatment of steels

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Heat treatment of steels

cold work

hot work

INVESTMENT
CASTING

INVESTMENT
CASTING

Principle of Operation:

Principle of Operation:

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Heat treatment of steels

Advantages:
a. smoother cavity surface permits easier flow of molten
metal and better surface finish
b. good dimensional accuracy
c. mould collapsibility minimizes cracks in casting
d. can be mechanized for mass production

Principle of Operation:
5. The patterns are removed, and the two halfshells joined together to form the mould.
6. Molten metal is poured into the mould. When the
metal solidifies, the shell is broken to get the
part.

cold work

casting process

casting process

Heat treatment of steels

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15/7/2014

cold work

hot work

casting process

Heat treatment of steels

cold work

hot work

casting process

Heat treatment of steels

INVESTMENT
CASTING
Advantages:
a. parts of great complexity and intricacy can be cast
b. close dimensional control and good surface finish
c. wax can usually be recovered for re-use
d. additional machining is not required.

List FIVE (5) tools used in sand casting:

Disadvantages:
a. many processing steps are required
b. relatively expensive process

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cold work

hot work

casting process

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Heat treatment of steels

List FIVE (5) tools used in sand casting:

a.
b.
c.
d.
e.
f.
g.
h.
i.

Moulding flask
Strip bar
Ladle
Gate cutter
Rammer
Vent rod
Sprue
Core
Pattern
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