Mech.

Eng. Dept.

Lecture 3

Fundamentals of Metal
Casting 02

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Eng. Dept.

Text Books
1.Manufacturing Engineering and Technology,
Serope Kalpakjian, Steven R. Schmid Pearson
Education, Seventh Edition.

2.Fundamentals-of-modern-manufacturing,
Mikell.P.Groover 4th-edition.

3.Foundry technology, Peter Beeley, Second edition

2001.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Fluidity of Molten Metal Eng. Dept.

The capability of molten metal to fill mold cavities is called fluidity,

which consists of two basic factors:

(1) characteristics of the molten metal and
(2) casting parameters.

Although complex, the term castability generally is used to describe

the ease with which a metal can be cast to produce a part with good
quality.

Castability includes not only fluidity, but the nature of casting

practices as well.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Fluidity of Molten Metal Eng. Dept.

The following characteristics of molten metal influence

fluidity:

1. Viscosity. As viscosity and its sensitivity to temperature

increase, fluidity decreases.

2. Surface Tension. A high surface tension of the liquid

metal reduces fluidity. Because of this, oxide films on the
surface of the molten metal have a significant adverse effect
on fluidity; for example, an oxide film on the surface of pure
molten aluminum triples the surface tension.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Fluidity of Molten Metal Eng. Dept.

3. Inclusions. Because they are insoluble, inclusions can

have a significant adverse effect on fluidity. This effect can
be verified by observing the viscosity of a liquid (such as oil)
with and without sand particles in it; the liquid with sand in
it has a higher viscosity and, hence, lower fluidity.

4. Solidification pattern of the alloy. The manner in which

solidification takes place can influence fluidity. Moreover,
fluidity is inversely proportional to the freezing range: The
shorter the range (as in pure metals and eutectics), the higher
the fluidity. Conversely, alloys with long freezing ranges
(such as solidsolution alloys) have lower fluidity.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Fluidity of Molten Metal Eng. Dept.

The following casting parameters influence fluidity and also influence the fluid flow and
thermal characteristics of the system:

1. Mold Design. The design and dimensions of the sprue, runners, and risers all influence
fluidity.
2. Mold Material and Its Surface Characteristics. The higher the thermal conductivity of
the mold and the rougher its surfaces, the lower the fluidity of the molten metal.
Although heating the mold improves fluidity, it slows down solidification of the metal;
thus, the casting develops coarse grains and hence has lower strength.
3. Degree of Superheat. Superheat (defined as the increment of temperature of an alloy
above its melting point) improves fluidity by delaying solidification. The pouring
temperature often is specified instead of the degree of superheat, because it can be
specified more easily.
4. Rate of Pouring. The slower the rate of pouring molten metal into the mold, the lower
the fluidity, because of the higher rate of cooling when poured slowly.
5. Heat Transfer. This factor directly affects the viscosity of the liquid metal.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Fluidity of Molten Metal Eng. Dept.

Castability of different
metals and alloys
E= excellent, G = good,
F= fair, D= difficult

Spiral
A test method for fluidity using a spiral mold
mold. The fluidity index is the length of
the solidified metal in the spiral passage.
The greater the length of the solidified
metal, the greater is its fluidity.

16MECH03C: Production Technology 2 7

Dr. Mohamed Zaky
 Mech.
Variables influencing Fluidity Eng. Dept.

Temperature

Influence of superheat on fluidity: (a) pure metals (b) alloys

Foundry Technology
16MECH03C: Production Technology 2 Dr. Mohamed Zaky
 Mech.
Variables influencing Fluidity Eng. Dept.

Relationship
between
composition and
fluidity of leadtin
alloys

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Solidification and cooling Eng. Dept.

(a) Temperature as a function of time

for the solidification of pure metals. (b) Density as a
Note that the freezing takes place at a function of time
constant temperature.
16MECH03C: Production Technology 2 10
Dr. Mohamed Zaky
 Mech.
Alloy Solidification Eng. Dept.

Phase diagram for a copper - Cooling curve for a 50%Ni-50%Cu

nickel alloy system composition during casting.

16MECH03C: Production Technology 2 11

Dr. Mohamed Zaky
 Mech.
Cast Structures of Solidified Metals Eng. Dept.

Three cast structures of

metals solidified in a
square mold:
(a) pure metals;
(b) solid-solution alloys;
(c) structure obtained by
using nucleating
agents.

16MECH03C: Production Technology 2 12

Dr. Mohamed Zaky
 Mech.
Solidification Time Eng. Dept.

The rate at which growth of the solid occurs depends on the cooling
rate, or the rate of heat extraction. A higher cooling rate produces
rapid solidification, or short solidification times. The time ts required
for a simple casting to solidify completely can be calculated using
Chvorinovs rule:

where V is the volume of the casting and represents the amount of heat that must be removed before freezing
occurs,
A is the surface area of the casting in contact with the mold and represents the surface from which heat can be
transferred away from the casting,
n is a constant (usually about 2),
and B is the mold constant. The mold constant depends on the properties and initial temperatures of both the
metal and the mold.
This rule basically accounts for the geometry of a casting and the heat transfer conditions. The rule states that, for
the same conditions, a casting with a small volume and relatively large surface area will cool more rapidly.

Askeland Science and Engineering of Materials Six Edition

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Solidification Time Eng. Dept.

Example 9.2
Redesign of a Casting for Improved Strength

Your company currently is producing a disk-shaped brass casting 2

in. thick and 18 in. in diameter. You believe that by making the
casting solidify 25% faster, the improvement in the tensile
properties of the casting will permit the casting to be made lighter
in weight. Design the casting to permit this. Assume that the mold
constant is 22 min/in.2 for this process. and n = 2.

14

Askeland Science and Engineering of Materials Six Edition

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Solidification Time Eng. Dept.

Example 9.2 SOLUTION

If d is the diameter and x is the thickness of the casting, then
the volume, surface area, and solidification time of the 2-
in.thick casting are:

15

Askeland Science and Engineering of Materials Six Edition

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Solidification Time Eng. Dept.

Example 9.2 SOLUTION (Continued)

Since the casting conditions have not changed, the mold
constant B is unchanged. The V/A ratio of the new casting is:

16

Askeland Science and Engineering of Materials Six Edition

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Solidification Time Eng. Dept.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Shrinkage of a cylindrical casting duringMech.
SHRINKAGE solidification and cooling Eng. Dept.

(0) Starting level of molten

metal immediately after
pouring;
(1) Reduction in level caused
by liquid contraction during
cooling;
(2) Reduction in height and
formation of shrinkage
cavity caused by
solidification shrinkage;
(3) Further reduction in
height and diameter due to
thermal contraction during
cooling of the solid metal.
For clarity, dimensional
reductions are exaggerated
in sketches.

16MECH03C: Production Technology 2 18

Dr. Mohamed Zaky
 Mech.
Shrinkage in metals and alloys Eng. Dept.

16MECH03C: Production Technology 2 19

Dr. Mohamed Zaky
 Mech.
Eng. Dept.

Pattern Making

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Pattern Making Eng. Dept.

A. Requirements
1. The type and form of material to be used
2. The type of pattern to suit the method of moulding
3. The need for corebox
4. Constructional details, the need for loose pieces and
coreprint
5. The value of allowance to be used
6. The method of gating and feeding to be allowed

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.

B. Pattern Materials
The selection of pattern materials depends on
factors such as:
Service requirements such as quantity, quality
and intricacy of casting, minimum thickness
desired, degree of accuracy and finish
requirements
The possibility of design change
Type of moulding process
Possibility of repeated orders
16MECH03C: Production Technology 2 Dr. Mohamed Zaky
 Pattern Making Mech.
Eng. Dept.
B. Requirements of Pattern Materials
1. Easily worked, shaped and joined
2. Light in weight for facility in handling and working
3. Strong, hard, durable (high strength to weight)
4. Resistance to wear and abrasion, to corrosion and
to chemical actions
5. Dimensional stability and unaffected by variation in
temperature and humidity
6. Available at low cost
7. Can be repaired or even re-used
8. Having ability to take a good surface finish
16MECH03C: Production Technology 2 Dr. Mohamed Zaky
 Pattern Making Mech.
Eng. Dept.

Pattern Materials

1.Wood
2.Metals
3.Plasters
4.Plastic and rubbers (polymers)
5.Expendable Pattern (Waxes, polystyrene
foam and mercury)
6.Old castings

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.

Pattern Allowance
1.Contraction allowance
2. Machining allowance
3. Draft or taper allowance (1-5 degrees for external
surfaces and 2-5 degrees for internal surfaces)
4. Rapping and shake allowance
5. Distortion allowance.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.
1. Contraction allowance

Single Phase material

L-L
(Liquid- Liquid
contraction, L-L
liquid-solid
Volume, mm3
L-S L-S1
contraction and Multi phase material
S-S
solid-solid
contractions) S1-S1
S2-S3 S1-S2
10.5mm/1000mm S2-S2
in Cast Iron and S3-S3

21mm/1000mm in
steel.
Temperature, 0C
Pattern makers use a contraction ruler for each metal to compensate the S-S contraction in
the pattern dimensions
16MECH03C: Production Technology 2 Dr. Mohamed Zaky
 Pattern Making Mech.
Eng. Dept.

Machining allowance
Machining or finish allowance is the extra material added to certain
parts of the casting to enable their finishing or machining to the
required size
The amount of machining allowance affected by:
1. The method of moulding and casting, hand moulding, machine moulding, sand
mould casting or metallic mould casting.
2. Size and shape of the casting
3. The casting orientation, greater allowance is required on the top surface of the
mould
4. Degree of accuracy required and finish

Machining allowance 3mm in cast iron, 4mm in steel and 1.5mm non-ferrous. To be
added for all dimensions except holes to be subtracted from.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Example Mech.
Eng. Dept.

Calculate the pattern dimensions for the following

cast to be made from plain carbon steel that having
contraction allowance of 21mm/1000mm and
machining allowance of 4mm.
L= 200 mm

W= 150 mm

D = 80 mm

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.
Pattern Technological Consideration
1. Core Prints (Horizontal Core print, Vertical, Cover Core print, wing core
print, balanced coreprint)
2. Loose Pieces (some times the product can have protruding part that
make the ramming difficulty and
3. Stop off Cover Core

Horizontal Core

Vertical Core Wing Core

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.

Coreprint support calculation

Core print must support the buoyancy force of the liquid metal
Practical Method:
In case of the balanced core, Length of coreprint of core diameter D should be 2D
Unbalanced core of length L, the core print length should be L

Theoretical Method:

Buoyancy force of liquid metal = core volume (liquid metal density core density)
B.F. = V (metal core) N
V: Volume of core in the mould cavity cm3
Liquid metal density (N/cm3)
Core material density (N/cm3)

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.
Core print support calculation
The mould holding force is the force that support the core against the buoyancy force and
prevent the core from movement, so the holding force must be higher than the B.F.

Core print holding force (H.F.) = . A

Where A is the core print projected area (cm2) and is the compressive strength of mould
(N/cm2)

H.F. = B.F.
. A = V (metal core) then for balance . A - V (metal core) = 0

. D.X = (D2/4) *L (metal core)

X = length of the core print, cm
L= Length of the core in the mould, cm
D = Diameter of the core, cm
Length of the core print should be more than X as X represent the length for balance
with B.F.
16MECH03C: Production Technology 2 Dr. Mohamed Zaky
 Pattern Making Mech.
Eng. Dept.

Loose Pieces
some times the product can have protruding
part that make the ramming difficulty and also
the pattern withdrawing.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.

Stop Off
Extra parts added to the pattern to support it during
ramming in case of thin sections. After ramming the space
made by the stop off can be filled with sand.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Making Mech.
Eng. Dept.

Pattern Types
Pattern are of several types each satisfying casting
requirement
1. Loose pattern of one piece type, split type, loose piece
type and with follow board.
2. Gated pattern
3. Special pattern and device such as sweep or skelton
type
4. Match plate pattern or plate mounted pattern.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Types Mech.
Eng. Dept.

1. Loose Pattern
Basic sequences in loose pattern moulding.
(a) Plain shape: single parting formed by flat surface of pattern;
(i) bottom part rammed on flat board,
(ii) top part rammed on bottom part after turnover,
(iii) complete mould after separation, pattern withdrawal and
closing.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Types Mech.
Eng. Dept.
1. Loose Pattern
Basic sequences in loose pattern moulding.
(b) Oddside employed to bed one-piece pattern to parting surface;
(iv) bottom part rammed on oddside,
(v) top part rammed on bottom part after turnover and removal of
oddside,
(vi) complete mould after separation, pattern withdrawal and
closing.

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Types Mech.
Eng. Dept.

1. Loose Pattern
(c) Split pattern;
(iv) bottom part rammed from half pattern on flat board,
(v) top part rammed on bottom part after turnover and positioning
of second half pattern,
(vi) complete mould after separation, pattern withdrawal and closing

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Types Mech.
Eng. Dept.

Mounted pattern practice

This obviates the need to form a parting surface during moulding:
each half pattern is mounted on its own flat or contoured plate and
the mould parts can be made independently of one another,
whether by hand or on moulding machines

Mounted pattern assembly for machine moulding

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Types Mech.
Eng. Dept.
Matchplate pattern
Normal pattern plate practice requires separate plates for top and bottom part
production. A matchplate pattern enables a complete mould to be produced in a single
operational sequence. In this system the pattern elements forming the cope and drag
are mounted on opposite faces of the same plate. The plate is then sandwiched
between the boxes for the successive production of each mould part, the whole
assembly being aligned with long pins: the parts are readily realigned on removal of the
matchplate. The sequence is illustrated in Figure 8.5.

Hand or machine moulding from matchplate pattern: (a) bottom part rammed with
matchplate supported on empty boxpart, (b) top part rammed after turnover, or separately
supported on empty boxpart, (c) complete mould after pattern withdrawal and closing

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Pattern Types Mech.
Eng. Dept.

Gated Pattern
A gated pattern is simply one or more loose patterns having attached gates
and runners.

Because of their higher cost, these patterns are used for producing small castings
in mass production systems and on molding machines

Runner
Gates

16MECH03C: Production Technology 2 Dr. Mohamed Zaky

 Mech.
Eng. Dept.

End of Lecture 3

16MECH03C: Production Technology 2 Dr. Mohamed Zaky