1.3 Fundamentals of Metal Casting - Fluidity of Molten Metal - Different Types of Casting Process - Defects in Casting - Testing and Inspection of Casting

MEE 205
Fundamentals of Manufacturing Process

Unit I
Metal Casting Process
Table of Contents
Fundamentals of metal casting
Fluidity of molten metal
Sand casting
Shell mold casting
Investment casting
Plaster mold casting

Die casting
Defects in casting
Testing and inspection of casting
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Fundamentals of Metal Casting

The casting process basically involves
Pouring of molten metal into a mold pattern after the part
to be manufactured
Allowing the molten metal to cool
Removing the metal from the mold
The important considerations in casting operations are

The flow of molten metal into the mold cavity
The solidification and cooling of the metal in the mold
The influence of the type of mold material
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Fundamentals of Metal Casting Gating system
[www.hackaday.io/project/2434/logs]
[http://nptel.ac.in/courses]
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A good gating design should ensure proper distribution of
molten metal without excessive temperature loss ,turbulence,

gas entrapping and slags
Very
slow pouring, require longer filling time and
solidification will start even before filling of mould

This can be restricted by using super heated metal, but in
this case gas solubility will be a problem

Faster pouring can erode the mould cavity
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So designing the gating system is important and it depends
on the metal and molten metal composition. For example,

aluminium can get oxidized easily
Gating systems refer to all those elements which are
connected with the flow of molten metal from the ladle to

the mould cavity
The purpose of gating system is to deliver the molten metal
to mold
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The elements of a gating system are
Pouring Basin
Sprue
Sprue Base Well
Runner
Runner Extension
Gate or Ingate
Riser
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Characteristics of a gating system

A gating system should be able to do the following
Permit complete filling of the mold cavity
Requires minimum time to fill the mold cavity
Minimum turbulence so as to minimize gas pickup
Regulate rate at which molten metal enters the mold cavity

Prevent unwanted material from entering mould cavity
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Characteristics of a gating system (contd..)

Establish suitable temperature gradients
No mould erosion
Simple and economical design
Easy to implement and remove after solidification

Maximum casting yield
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Fluidity of molten metal

The capability of molten metal to fill mold cavity is called
fluidity. It consists of two basic factors

Characteristics of the molten metal
Viscosity, Surface tension, Inclusions
Solidification pattern of the metal / alloy
Casting parameters
Mold design, Mold materials and surface characteristics,

Rate of pouring
Degree of superheat, Heat transfer
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Fluidity of molten metal (contd..)

Characteristics of molten metal
Viscosity resistance to flow its sensitive to temperature
(viscosity index) increases, fluidity decreases

Surface tension - the elastic tendency of liquids which makes
them acquire the least surface area possible high surface

tension of the liquid metal reduces fluidity. Oxide films on the
surface of molten metal have a significant adverse effect on
fluidity
Example: an oxide film on the surface of pure molten
aluminium triples the surface tension
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Inclusions can have adverse significant 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

Solidification pattern of alloy the manner in which
solidification tales place, can influence fluidity. Fluidity is

inversely proportional to freezing range.
Shorter the range, higher the fluidity. Conversely lower fluidity for
longer freezing range
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Mold design the design and dimensions of the sprue,
runners and risers all influence fluidity

Mold material and its surface characteristics the higher
the thermal conductivity of the mold and the rougher the

surfaces, the lower the fluidity of the molten metal.
Degree of superheat superheat improves fluidity by
delaying solidification
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Rate of pouring slower the rate of pouring molten metal
into the mold, the lower the fluidity because of the higher
rate of cooling
Heat transfer factor affects directly the viscosity of the
liquid metal
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Types of Casting process

Sand casting
Basic Permanent Mold casting
Ceramic Mold
Casting
Shell Mold
Casting
Vacuum casting
Expanded
Polystyrene
casting
Slush Casting
Permanent mold casting
Expandable mold casting
Plaster Mold
Casting
Investment
Casting
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Pressure Casting
Vacuum Permanent Mold Casting
Die casting
Centrifugal Casting
Centrifuge Casting
Ingot Manufacture
Continuous Casting
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Sand Casting
Sand casting typically relies on silica-based materials, such as
synthetic or naturally-bonded sand

Casting sand generally consists of finely ground, spherical
grains that can be tightly packed together into a smooth

molding surface
The casting is designed to reduce the potential for tearing,
cracking, or other flaws by allowing a moderate degree of

flexibility and shrinkage during the cooling phase of the
process
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Sand Casting Process (contd..)

The sand can also be strengthened with the addition of clay,
which helps the particles bond more closely

Many automotive products, such as engine blocks and
housings, are manufactured through sand casting

Its main advantages as a casting process include
Relatively inexpensive production costs, especially in

low-volume runs
The ability to fabricate large components
A capacity for casting both ferrous and non-ferrous

materials, low cost for post-casting tooling
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Disadvantages of Sand Casting Process

Despite its benefits, sand casting yields a lower degree of
accuracy than do alternate methods and it can be difficult to
sand cast components with predetermined size and weight

specifications
Furthermore, this process has a tendency to yield products
with a comparatively rough surface finish
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Plaster Mold Casting Process

Plaster casting is similar to the sand casting process, using a
mixture of gypsum, strengthening compound, and water in

place of the sand
The plaster pattern is typically coated with an anti-adhesive
compound to prevent it from becoming stuck against the

mold, and the plaster is capable of filling in any gaps around
the mold
Once the plaster material has been used to cast a part, it
usually cracks or forms defects, requiring it to be replaced

with fresh material
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Plaster Mold Casting Process (contd..)

The advantages offered by plaster casting include
A very smooth surface finish
The ability to cast complex shapes with thin walls
The capacity for forming large parts with less expense than
other processes, such as investment casting

A higher degree of dimensional accuracy than that of sand
casting
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Disadvantages of Plaster Mold casting Process

This process tends to be more expensive than most sand
casting operations, and may require frequent replacements

of plaster molding material
It is usually more effective and cost-efficient when the quality
of the surface finish is an important requirement
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Investment Casting Process

Investment casting uses a disposable wax pattern for each
cast part.
The wax is either injected directly into the mold or pre-
coated with a liquid refractory material before injection.

Molten forming material is then poured into the mold and
allowed to harden and set into the shape of the wax pattern.
The component is then ejected, while the wax pattern is
melted out of the casting and made available for reuse.
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Investment Casting Process (contd..)

Investment casting is often used to manufacture parts for the
aerospace and automotive industries, as well the military

Some of the central advantages of using an investment casting
process include
A high degree of accuracy and precise dimensional results
The ability to create thin-walled parts with complex geometries
The capacity for casting both ferrous and non-ferrous materials

Relatively
high-quality surface finish and detail in final
components
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Disadvantages of Investment Casting Process

Although it is highly precise, investment casting is usually
more expensive than other comparable casting techniques,
and is typically only cost-efficient when sand or plaster

castings cannot be used
However, the expense can sometimes be compensated for
with reduced machining and tooling costs due to investment
castings quality surface results
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Shell Mold Casting Process
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Shell Mold Casting Process (contd..)

5
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Die Casting Process

Die casting is a method of molding materials under high
pressure and usually involves non-ferrous metals and alloys,
such as zinc, tin, copper, and aluminium

The mold is coated with lubricant to help regulate the dies
temperature and to assist with component ejection

Molten metal is then injected into the die under high
pressure, which remains continuous until the work piece
solidifies
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Die Casting Process (contd..)

This pressurized insertion is rapid, preventing any segment
of the material from hardening before being cast

After the process is completed, the component is taken out of
the die and any scrap material is removed

A few of the major advantages provided by die casting
include
Close size and shape tolerances
High component dimensional consistency and uniform
design
A reduced need for post-casting machining
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Disadvantages of Die casting Process

Despite its advantages, die casting has relatively high tool
costs, making it more cost-efficient in high-volume product

runs.
It can also be difficult to ensure the mechanical properties of
a die cast component, meaning these products usually do not

function as structural parts
Topics for self study: Ceramic Mold Casting and

Centrifugal casting process
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Castings Inspection Methods

Non-Destructive testing methods
Non-destructive testing gives the metal casting facility the
capability of assuring the quality of a casting without
destroying it.
1. Visual Inspection Method - sand holes, excessively rough
surface, surface shrinkage, blowholes, misruns, cold shuts,
and surface dross or slag
2. Dimensional Inspection - To ensure a part meets

dimensional requirements, such as tolerances, a metal
casting facility can check the dimensional accuracy of a part
manually or with a coordinate measuring machine (CMM).

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Castings Inspection Methods (contd..)

3. Dye Penetrant and Fluorescent Powder Testing
For tiny cracks, pores or other surface glitches that are
hard to detect by the human eye, dye penetrant testing is

used for both ferrous and nonferrous materials.
In this method, a colour dye solution is applied to the
surface of the casting.

The dye, which is suspended in penetrating oil, will find its
way into the surface defects.

When a special developer is applied, the defects are clearly
indicated.
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4. Magnetic particle inspection is quick, inexpensive and
sensitive to defects, particularly shallow (0.003 in.) surface
cracks and other lineal indications.

It detects small cracks on or near the surface of ferrous
alloys that can be magnetized (basically any ferrous alloy
except austenitic material). A high-amperage, low-voltage

current is passed through the casting, which establishes a
magnetic field.
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5. Ultrasonic Testing - Internal defects that are detected by
radiography may also be detected by sound.

In casting inspection, ultrasonic testing uses high
frequency acoustic energy that is transmitted into a
casting. Because ultrasonic testing allows investigation of
the cross-sectional area of a casting, it is considered to be

a volumetric inspection method.
The high frequency acoustic energy travels through the casting
until it hits the opposite surface or an interface or defect.
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6. Eddy Current Inspection - The eddy current inspection
method is applied to the detection of cracks at or near the

surface.
An electrically charged coil carrying an alternate current

causes an eddy current to flow in any nearby metal.
The eddy current may react on the coil to produce

substantial changes in its reactivity and resistance, and
that reaction is used to pinpoint small cracks or defects
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7. Pressure Leak Testing - When a casting is specified to be
pressure tight or leak-proof, it is often tested by sealing

openings in the casting and pressurizing it with air, inert
gas or water.
When water, or hydrostatic, pressure is used, water seeping
through the casting wall indicates leaks.

If air or gas pressure is used, the pressurized casting is put into a
tank of clear water.
The appearance of bubbles indicates the air has penetrated

through the casting wall and a leak is present.
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References
Elaheh
Ghassemieh
(2011).
Materials
in
Automotive
application, State of the Art and Prospects, New Trends and

Developments in Automotive Industry, Prof. Marcello
Chiaberge (Ed.), ISBN: 978-953-307-999-8, InTech, Available

from: http://www.intechopen.com/books/new-trends-anddevelopments-in-automotiveindustry/
materials-in-
automotive-application-state-of-the-art-and-prospects
P. Blain (2012) Steel perspectives for automotive industry
Lotus Engineering, 2010

www.thomasnet.com
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1.3 Fundamentals of Metal Casting - Fluidity of Molten Metal - Different Types of Casting Process - Defects in Casting - Testing and Inspection of Casting

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MEE 205

Fundamentals of Manufacturing Process

Plaster mold casting

MEE 205 Fundamentals of Manufacturing Process

Fundamentals of Metal Casting

Pouring of molten metal into a mold pattern after the part

The important considerations in casting operations are

MEE 205 Fundamentals of Manufacturing Process

Fundamentals of Metal Casting Gating system

MEE 205 Fundamentals of Manufacturing Process

Fundamentals of Metal Casting Gating system

molten metal without excessive temperature loss ,turbulence,

slow pouring, require longer filling time and

solidification will start even before filling of mould

this case gas solubility will be a problem

MEE 205 Fundamentals of Manufacturing Process

Fundamentals of Metal Casting Gating system

on the metal and molten metal composition. For example,

connected with the flow of molten metal from the ladle to

MEE 205 Fundamentals of Manufacturing Process

Fundamentals of Metal Casting Gating system

MEE 205 Fundamentals of Manufacturing Process

Characteristics of a gating system

Regulate rate at which molten metal enters the mold cavity

MEE 205 Fundamentals of Manufacturing Process

Characteristics of a gating system (contd..)

Easy to implement and remove after solidification

MEE 205 Fundamentals of Manufacturing Process

Fluidity of molten metal

fluidity. It consists of two basic factors

Mold design, Mold materials and surface characteristics,

MEE 205 Fundamentals of Manufacturing Process

Fluidity of molten metal (contd..)

(viscosity index) increases, fluidity decreases

them acquire the least surface area possible high surface

aluminium triples the surface tension

MEE 205 Fundamentals of Manufacturing Process

Fluidity of molten metal (contd..)

This effect can be verified by observing the viscosity of a

liquid such as oil with and without sand particles in it

solidification tales place, can influence fluidity. Fluidity is

longer freezing range

MEE 205 Fundamentals of Manufacturing Process

Fluidity of molten metal (contd..)

runners and risers all influence fluidity

the thermal conductivity of the mold and the rougher the

MEE 205 Fundamentals of Manufacturing Process

Fluidity of molten metal (contd..)

MEE 205 Fundamentals of Manufacturing Process

Types of Casting process

Basic Permanent Mold casting

Expandable mold casting

MEE 205 Fundamentals of Manufacturing Process

synthetic or naturally-bonded sand

grains that can be tightly packed together into a smooth

cracking, or other flaws by allowing a moderate degree of

MEE 205 Fundamentals of Manufacturing Process

Sand Casting Process (contd..)

which helps the particles bond more closely

housings, are manufactured through sand casting

Relatively inexpensive production costs, especially in

The ability to fabricate large components

A capacity for casting both ferrous and non-ferrous