Name: Alan T. Loquite Jr.

Date: Aug. 6, 2012

Activity No. 2 Aluminum Casting

Objectives:

After the experiment, the student will be able to: 1. Perform the basic procedure on mixing plaster of paris 2. Perform the basic melting of aluminum 3. Execute the steps on casting aluminum in a mold 4. Enumerate the benefits and limitations of casting in the society

Materials/Equipment:

Plaster of Paris Water Spatula Molder Mixing Trough Heater Rag Camera Face mask Gloves Grinder Furnace Metal cutting Scissors Goggles Vise grips

Introduction Casting is a manufacturing process that melts a solid material and usually poured it in a molder and allows it to harden or solidify. Casting is commonly used in making art, making jewelries, sculptures and also making practical devices.

Procedure: A. Making a mold 1. Wear Safety mask before experiment to avoid health problems. 2. Fill the mixing container with 1 part water. 3. Add 2 parts of Plaster of Paris in the container and permit it to fall evenly on the surface of the water. 4. Shake the container gently and let the water and plaster mix until the mixture thickens. 5. Pour the mixture on the molder. 6. Break the lumps and bubbles by using a spatula or by tapping the hard surface of the molder. 7. Wait for the mixture until it sets and let it dry and hardens for 5-10 minutes.

B. Melting and casting of aluminum

1. Wear protective clothing to avoid accidents. 2. Cut metal to small pieces using metal cutting scissors. 3. Prepare the Furnace and set the temperature. 4. When the temperature is ready, put the shredded metal pieces in the furnace and wait until it turns to liquid. 5. When it is in liquid form use a vise grip to hold the molten metal and pour it directly to the molder. 6. Let it cool down and remove it from the molder and wash it with water. 7. Grind the excess parts using a grinder.

ILLUSTRATIONS: MOLD:

ALUMINUM CAST:

Data and Results:

1. What is casting? What is the most common metal used in casting? Casting is a manufacturing process that melts a solid material and usually poured it in a molder and allows it to harden or solidify. Casting is commonly used in making art, making jewelries, sculptures and also making practical devices. Zinc is one of the most common metal used in casting because it is easily available, melts at a low enough temperature that you can melt it on the stove, with effort, or with a propane torch and quite non-toxic, certainly far less toxic than lead. Aluminum is also one of the most common metals used in casting because it melts higher than zinc, tin, and lead, but not nearly as high as copper. Aluminum is also easily available and you can get a better casting result because cast aluminum contains silicon which greatly enhances the ability of the molten metal to conform to details in the mold.

2. What is plaster of paris? Is there any substitute for plaster of paris as mold? Why or why not? Plaster of Paris is a type of plaster that has been used for centuries in architecture, fireproofing and in some medical applications. It is a white powder that usually comprised of gypsum and when added to water it forms a slurry or a thick liquid mixture. This slurry or thick liquid mixture can be poured in a molder and can be molded in a variety ways, and as it sets, a firm matrix is created, creating a solid shape which is also very smooth. There is a substitute for plaster of paris. You can use clay or flour. But Plaster of paris is the best because it is cheaper, more durable and can sustain high temperature compare to others.

3. What is the best way to remove the impurities in the molten aluminum? Where do these impurities come from? Impurities in molten aluminum may come from exogenous and endogenous inclusions. Exogenous inclusion may come from the melt environment as the refractory linings of furnaces, ladles, reactors or launders. Endogenous Inclusion are formed from the melt during production. Impurities may be foreign metals or dissolved gasses. Foreign metals like Li, Na, Ca coming from the electrolyte. Dissolved gas in Aluminum is Hydrogen because it does not form compounds with aluminum as other gasses.

Impurities can be remove by stirring the molten metal to create a vortex. Impurities can also be removed by scraping it out using a stick or metal ladle when aluminum is in liquid form.

4. Give the advantages and disadvantages of casting aluminum using the laboratory melting furnace:

Advantages Aluminum melts faster and readily available compare to other metals.

Disadvantages Scent of molten metal is not good for the health.

Good surface finish.

Cannot be used for large casting because laboratory furnace capacity has limits.

Aluminum casting retains a high degree of durability.

High shrinkage and susceptibility to shrinkage defects.

Aluminum casting is versatile.

Low Ductility

Easy to use.

Susceptibility to hot cracking

5. What is shrinkage? When does this occur? Shrinkage is a significant factor in thermoforming large precision parts and allowances must be made for it in the design of the part. Shrinkage usually occurs due to heat loss as it cools to room temperature.The part continues to shrink as the hot center or core of the plastic cools. This shrinkage ceases when temperature equilibrium is reached in the cooled material.Shrinkage takes place in three basic forms: mold shrinkage, after-mold shrinkage, and in-service shrinkage and expansion.

References: http://www.cast-parts.com/castings/advantages-of-cast-aluminum-parts/ http://www.wisegeek.com/what-is-cast-aluminum.htm http://www.tridentcomponents.com/aluminum-die-casting.html http://www.bayermaterialsciencenafta.com/checklist/shrinkage.html http://www.castwell-castings.com/Advantages-Disadvantages-77.html