Metal Casting and

Forming

ALL manufacturing starts here!

What is Metal Casting?

When liquid metal is poured into a
mold, then solidifies and takes the
form of the mold.
Iron, steel, aluminum, brass, bronze,
magnesium, and zinc are all metals
that can be casted.

Patterns
Part to be made
Allow for shrinkage
(1-2%)

Cast iron 1/8 per foot

Steel 1/4 per foot
Aluminum 5/32 per
foot

Metal, plastics, or
wood
Single or multiple
pieces

Pattern removed from mold

Patterns cont.
Draft to allow removal from the mold (2-3*)
Commonly oversized for machinability

Ice cube trays have draft angles.

Castings
Castings: Parts made using casting
process
Molds or Patterns used to make
castings can be made of one or more
pieces.

Foundry
A factory specializing in metal casting.
Dirty, hot, loud hard but rewarding
work
Modern Foundry Video

Different Casting
Processes
1. Green Sand Casting
2. Permanent & Die Casting
3. Investment (Wax &
Foam)
4. Continuous
5. Centrifugal

Sand Casting
Pattern is formed into a sand cast.
Liquid metal is poured into the sand
cast.
A sand cast is a ONE time use casting
Mold is destroyed to remove
casting/part

Sand Casting
Produce castings ofvirtually any size and
weight.
Common for prototyping & low volume
production.

Sand Mold
Section view of mold showing spru, runner
and gating system, risers (feeders), cores
and pattern draft.

Permanent Mold
Casting

Mold is made of iron or steel

Molds are good for multiple uses
Used when poring large quantities of
identical parts

Permanent Mold Casting

Advantages: Consistent, Precise, tighter
tolerances
Disadvantages: very expensive to produce
molds

Permanent Die Casting

Similar to permanent mold casting
except that the metal is forced into the
mold under pressure
Large quantity production.

Investment Casting
(Lost
Wax)
Over 1,000 year old technology

Pattern is made of wax.

A ceramic shell is built around the wax pattern.
Wax pattern is melted out of the shell.
Molten metal is poured into the shell.
Investment Casting Video
Investment Casting Video 2

Investment Casting (Lost

Foam)

Styrofoam pattern is coated with a

refractory material and dry sand is
compacted around pattern.

Metal is poured
onto the foam &
instantly vaporized.

No draft required

Continuous Casting
Used to make large steel fixtures (iron plates,
beams)
Metal is melted in hopper & gravity fed
Metal taken as needed
Unused metal recycled into hopper

Centrifugal Casting
Used to produce
objects with large
holes such as cast iron
drain pipe
Mold is spun ~ 1000
RPM
Impurities gravitate to
the inside surface
Impurities machined
of

Modern Foundry
Processes

Engineering
Mold Making
Melting
Checking Gas Levels
Pouring
Shakeout
Degating
Heat Treating
Surface Cleaning
Finishing
Secondary Machining
Quality Control

Engineering

The best castings start with precise engineering

CAD software: concept to prototyping
Maximize production, minimize production cost
Maximize efficiency, consistency
Minimize waste

Design Engineering Video

Producing the Mold

Fine sand is compressed tightly around
pattern
Course sand used as fill

Producing the Mold

Melting Metal
Solid metal is placed into crucible
(melting pot)
Ceramic bowl that that withstands extreme
temps.

Crucible is placed in furnace

Slowly heated until metal is liquefied
Poured into mold.

Melting Temperatures

LEAD 700*F
ALUMINUM
1200*F

BRASS 1500*F
COPPER
2000*F

STEEL 2500*F
Aluminum is typically poured at 1350*F

Checking Gas
Levels

Gas levels: specific to alloy & pattern complexity

Quality Control: sample is taken and density is
measured
Porosity: Air pockets formed in metal

High gas levels Low gas levels

Low viscosity
More
porosity
Weaker
casting

More viscous
Less porosity
Stronger
casting

Altering Gas Levels

Too High

Argon or
nitrogen is
bubbled into
metal
Introduced at
the bottom
Bubbles rise
and catch
hydrogen
Bubbles rise to
top

Too Low

Potatoes are
added
Adds gas to metal
New sample taken

Pouring
Metal is poured into mold to solidify
Some molds require 4-5 pours
1-2% shrinkage common

Automatic Die Casting

Machine

Computerized casting machine that prevents

fluctuations in metal
Mold is rolled into machine
Metal is casted beneath via low pressure
Provides consistency for difficult molds

Shakeout
Solidified metal component is then
removed from its mold via shaking or
tumbling
Frees the casting from the sand
Runners and gates are still attached
Allows sand to be reclaimed and reused
Lowers foundry production cost
Old days sand went to landfill!

Shakeout Machine

Degating
Spru, runners, gates, and risers are removed
Torches, bandsaws, ceramic cutof blades, sledge
hammers
Specialized knockof machinery used if design
permits
Gating system (sprue, runner, gate) may equal
50% of a poor.
Gating components must be remelted as
salvage.
Important economic consideration

Heat Treating

Part baked in large oven at a controlled

temperature and time interval
Changes molecular grain for more strength
Heat Treated part is then quenched in bath
Adds strength to casting

Not all parts are

heat treated

Surface Cleaning
Casting is blasted with tiny steel bbs
Removes any sand or debris
May be used to achieve a particular
rough finish

Finishing
The final step in the process usually
involves grinding and sanding
Achieve dimensional accuracies, shape &
finish.
These steps are done prior to any final
machining.

Quality Control
CNC equipment forprecision gauging
Parts are x-rayed for imperfections
(Internal cracks, Porosity)

X-Ray Photograph

X-Ray Machine

Secondary Machining
Parts are machined using precise
CNC equipment.
Some foundries machine parts in
house & some sub-contract machine
shops
Secondary Machining Video

Tooling Up

Flask
Molding Board
Bottom Board
Rammer
Riddle
Trowel
Slick
Sprue Pin
Riser Pin

Lance Pyrometer
Tool used to identify molten metal
temperature.
Diferent types of metal poor better
at diferent temperatures.
Aluminum 1450*F

Ingots
Ingot: a solid piece of metal that has
been formed into a particular shape (such
as a brick) so that it is easy to handle or
stored

Flask & Boards

Flask
Cope - top
Drag bottom
Boards
Molding Board used on drag when
being rammed
Bottom Board placed on top of drag
when flipping the mold, supports the
bottom of the mold.

Sand Charactoristics

Sand grit is determined just like sand paper

Fine sand will give a smooth finish
Rough sand will give a rough finish
Sand is 6% moisture dont let it dry out
Shovel Used to mix & move sand
Riddle find sand around mold!
Sand allows gas to escape to

Slick, Sprue Pin, Riser

Pin
Slick Another tool used to flatten face of
the mold.
Sprue Pin Tapered wood or metal pin
used to form sprue hole
Riser Pin Wood or metal pin used to form
overflow

Vent Wire, Molders Bellow,

Bulb Sponge
Vent Wire - Small holes in mold to allow for gas
escape.
Bellow - Tool used to blow excess sand from the mold
cavity
Bulb Sponge Smoothens the edges of the pattern to
prevent loose sand from entering mold.

Sprue, Riser, & Gate

Cutters
Same purpose as pins but used after
the sand has been rammed/packed.
Tapered shank allows us to cut &
extrude.

Parting Compound
Sprinkled around pattern for easy
mold extraction
Baby powder or fine gritt sand may
be used

Hot Tips
Finish molding before you starting the
furnace!
Safety & Attention to detail

Keep sand covered or in a sealed container

when not in use!
Avoid melting aluminum cans!
Cans are coated with vinyl for protection
Best results are obtained from clean metal

DO NOT stir molten metal, this adds gas!

Always skim slag before pouring!

Safety
PPE: GLASSES, FACE SHIELD, SPATS, COAT,
GLOVES!
ALWAYS PRE-HEAT METAL !
NEVER ADD LIQUID OR MOISTURE!
PLACE HOT CASTINGS IN A SAFE PLACE!
NEVER SET CRUCIABLE ON CONCRETE!
NEVER LOOK DIRECTLY OVER MELTING POT!
KEEP AREA CLEAN!
DONT RUSH!
ALWAYS POUR WITH A PARTNER!
AVOID MOLDING NEAR EDGES OF FLASK!
NEVER LEAVE THE ROOM!
INSTRUCTOR MUST BE PRESENT!

A look at Local Foundries

Eck Industries
http://www.eckindustries.com/

Wisconsin Aluminum Foundry

http://www.wafco.com/drysand.htm

Bremer Manufacturing
http://www.bremermfg.com/