Sand casting

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Sand casting
Open riser Core Sand Vent Pouring basin(cup)

Cope

Blind Riser

Sand

choke Drag Mold Cavity Runner gate Sand

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Patterns in Sand casting

Patterns are made in the shape of the casting Pattern Materials: Wood, Plastic or metal. Size, shape, dimensional accuracy, number of components. Parting agents. One piece or multiple piece pattern

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Typical match plate pattern

Cope side

plate

Drag side

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Sand casting

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Sand casting

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Issues in Casting Shrinkage Porosity Piping Microstructure

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Shrinkage
Can amount to 5-10% by volume Gray cast iron expands upon solidification due to phase changes Need to design part and mold to take this amount into consideration

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Casting Defects

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Casting Defects

Cold shut

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Porosity
Types due to gases smooth bubbles due to shrinkage rough voids Not a problem for ingots parts that will be deformation processed as long as it is not exposed to air (corrosion) can be healed
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Porosity due to gases

Smooth bubbles result from entrapped gases solubility in liquid is high, in solid is low, so gas is rejected during cooling Sieverts law
S = kpg
0.5,

where

S = solubility k = constant pg = partial pressure of gas over melt

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Solution to reduce porosity due to gases

Control atmosphere Vacuum Proper venting to let gases out Proper design of runners and gates to avoid turbulence

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Porosity due to Shrinkage Rough bubbles - voids Stages cooling liquid rejects latent heat at melting point alloys become slushy - liquid and solid co-exist cooling solid

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Porosity due to Differential cooling Transition between thicker and thinner sections can lead to porosity

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Solutions to porosity / Shrinkage

Risers allow molten metal to flow into mold to make up for shrinkage Design flow so no part freezes early large channels Flexible molds allow metal to shrink, not hold metal Heating or cooling certain areas to maintain uniform cooling (thermit or chills) Uniform part thickness leads to uniform cooling, less residual stress
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Chills

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Pipe Defect
Due to shrinkage giving rise to a funnel-like cavity Solutions insulate top (glass wool) heat top (exothermic mixture - thermit)

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Micro structure - Dendrites

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Good castings Design rules

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Advantages of castings

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Disadvantages of castings

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Cost of castings

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