Casting

Casting Processes
Processes
Chapters
Chapters 10
10 -12
-12

R. Jerz

3/27/2006

Process
Process Equipment
Equipment and
and Cost
Cost
Foundry
z Furnaces
z

(previous video Ludken)

R. Jerz

3/27/2006

Types
Types of
of Melting
Melting Furnaces
Furnaces

Figure 11.26 Two types of melting furnaces used in foundries:

(a) crucible, and (b) cupola.
R. Jerz

3/27/2006

Process
Process Overview
Overview
Produce part in single step (near-net
shape)
z Can produce a wide variety of shapes and
sizes
z Complex shapes are possible
z Internal cavities are possible
z

R. Jerz

3/27/2006

Six
Six Basic
Basic Factors
Factors
1.
2.
3.
4.
5.
6.

Mold cavity
Melting process
Pouring technique
Solidification process
Removal of casting
Cleaning/finishing

R. Jerz

3/27/2006

Permanent
Permanent Mold
Mold Casting
Casting
z

Die casting

R. Jerz

3/27/2006

Typical
Typical Cast
Cast Parts
Parts

(c)
(a)

(d)

R. Jerz

3/27/2006

Die-Casting
Die-Casting Alloys
Alloys

R. Jerz

3/27/2006

Die-Casting
Die-Casting Dies
Dies

Figure 11.19 Various types of cavities in a die-casting die.

Source: Courtesy of American Die Casting Institute.

R. Jerz

3/27/2006

Cleaning
Cleaning &
& Finishing
Finishing
Remove cores
z Remove gates and risers
z Remove fins, flash
z Clean the surface
z Repair defects.
z Tumbling machines
z

R. Jerz

10

3/27/2006

Defects
Defects
z
z
z
z
z
z
z
z

Metal projects
Cavities
Discontinuities
Defective surface
Incomplete casting
Incorrect dimensions or shape
Inclusions (unwanted material)
Porosity
Shrinkage/gas

R. Jerz

11

3/27/2006

General
General Casting
Casting Design
Design Rules
Rules
Design the part to cast easily.
z Select the correct casting process
z Locate the parting line carefully
z Locate and design the gates, runners,
sprues, screens and risers
z Check for proper controls and good
practices
z

R. Jerz

12

3/27/2006

Design
Design for
for Casting
Casting
Avoid sharp corners
z Avoid thin sections
z Plan for shrinkage effects
z Use draft
z Allow material for machining
z

R. Jerz

13

3/27/2006