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Casting Process

Selection of casting process

• Type of metal.

• Number of castings required.

• Shape & size of castings.

• Dimensional accuracy required.

• Casting finish required.

• Economics.

Advantages and disadvantages of casting

Advantages disadvantages
Can create complex part geometries •Some casting methods are suited to mass production

Can create both external and internal shapes –Limitations on mechanical properties

Some casting processes are net shape; others are near –Poor dimensional accuracy and surface finish for some
net shape processes; e.g., sand casting

Can produce very large parts –Safety hazards to workers due to hot molten metals

Can create complex part geometries –Environmental problems


Basic Requirements of Casting Processes
The mould material has a higher melting point than the molten metal
The mould contains a cavity
The form of the cavity is determined by the pattern
The pattern is slightly larger than the finished casting
The pattern can be removed from the cavity

The Mold in Casting

(a) open mold, simply a container in the shape of the desired part
(b) closed mold, in which the mold geometry is more complex and requires a
gating system (passageway) leading into the cavity
Cores Requirements
1.In the green condition (green strength), there must be strong enough to retain
shape till it goes for baking.
2.In the hardened state (dry strength), it must be strong enough to handle the
forces (pressure) of casting.
3.Good refractorinessis required as the core is usually surrounded by hot metal
during casting or molding.
4.Permeability must be very high to allow for the escape of gases.
5.Collapsibility,As the casting or molding cools the core must be able to decrease
in size as the material shrinks.
6.Friability,they must be easy to remove during shakeout.
7.Smoothness, a smooth surface finish.
8.Low gas emission, a minimum generation of gases during metal pouring.
Chaplets
These are small metal supports that bridge the gap between the mold surface and
the core, but because of this become part of the casting.

There are situations where a core only uses one core print so other means are
required to support the cantilevered end. These are usually supplied in the form
of chaplets.

Gating system requirement


Requirements needed in gating system to achieve a free casting defects:
1- The metal should flow smoothly into the mould.
2- The unwanted material – slag – should not be allowed to enter the mould
cavity.
3- The metal entry into the mould cavity should be controlled.
4- A proper thermal gradient be maintained.
Factors controlling the functioning of gating system:
1. Type of pouring equipment, such as ladles, pouring basin etc.
2. Temperature/ Fluidity of molten metal.
3. Type and size of sprue.
4. Type and size of runner.
Furnace Selection
• Operating cost.
• Furnace capacity.
• Power availability (Heat source).
• Pollution and noise.
• Furnace atmosphere control

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