___________________________________

___________________________________

Materials & Processes in Manufacturing

___________________________________

ME 151

___________________________________
___________________________________
___________________________________
___________________________________

Chapter 15
Multiple Use Mold Casting Processes

2003 Bill Young

___________________________________

Introduction

___________________________________

Expendable Molds - ______ melting point materials and ________ castings

___________________________________

General shortcomings of the expendable-mold processes:

Dimensional Variations
Property Variations
Relatively Low Production Rates

___________________________________

Multiple-Use-Molds - _____ melting point materials and _________ castings

General shortcomings of the multiple-use-mold processes:

___________________________________
___________________________________

Limited to the lower melting point nonferrous metals and alloys

Part size is limited
Cost of tooling

___________________________________

Factors that affect mold life:

Alloy being cast
Mold material
Pouring temperature

Mold temperature
Mold configuration

2003 Bill Young

___________________________________
___________________________________

Multiple Use Mold Casting Processes

___________________________________
Permanent Mold or Gravity Die Casting

___________________________________

Slush Casting
Corthias Casting

___________________________________

Low-Pressure Permanent Mold Casting

___________________________________

Vacuum Permanent Mold Casting

___________________________________

____________

2003 Bill Young

___________________________________

Permanent Mold or Gravity Die Casting

___________________________________

Molten metal poured under the action of gravity alone

___________________________________

Disadvantages

Advantages
Reusable Mold
Good Surface Finishes
Good Dimensional Accuracy
Directional Solidification
Fast Cooling Rates

___________________________________

Lower Melting Point Alloys

Relatively Short Mold Life
Restricted Complexity of Mold
Risers Still Required
High Mold / Equipment Cost

___________________________________
___________________________________
___________________________________

Casting Examples:
Aluminum Pistons, Cooking Utensils, Electric Irons, Gear Blanks
Table 15-1 Page 327 (Process Overview)
2003 Bill Young

___________________________________

Slush Casting

___________________________________

Molten metal remains in the mold until a shell of desired thickness forms

___________________________________

Disadvantages

Advantages
Reusable Mold
Good Surface Finishes
Good Surface Detail
Fast Cooling Rates

___________________________________

Lower Melting Point Alloys

Variable Wall Thickness

___________________________________
___________________________________
___________________________________

Casting Examples:
Ornamental Objects, Candlesticks, Lamp Bases, Statuary

2003 Bill Young

___________________________________

Corthias Casting

___________________________________

Uses a plunger to create a positive pressure and force molten metal into
outer portions of the mold cavity
Advantages

___________________________________

Disadvantages

Reusable Mold
Good Surface Finishes
Good Surface Detail
Thinner Sections

___________________________________

Lower Melting Point Alloys

___________________________________
___________________________________
___________________________________

Casting Examples:
Thin Walled Ornamental Objects

2003 Bill Young

___________________________________

Low Pressure Permanent Mold Casting

___________________________________

Molten metal pushed into the mold using low pressure (5 - 15 PSI)

___________________________________

Advantages

___________________________________

Wide Variety of Metals

Metal not Exposed to Atmosphere
Mold Filled in Controlled Manner
No Risers Needed
Directional Solidification
High Yield Rates
Better Mechanical Properties

___________________________________
___________________________________
___________________________________

Disadvantages
High Mold / Equipment Cost
Slow Cycle Times
Figure 15-2 Page 327
2003 Bill Young

___________________________________

Vacuum Permanent Mold Casting

___________________________________

Molten metal pulled into the mold using a vacuum

___________________________________

Advantages

___________________________________

Same as the Low-Pressure Process

Thin Wall Castings
Excellent Surface Finishes
Superior Metal Cleanliness
Low Dissolved Gas Content
Better Mechanical Properties

___________________________________
___________________________________
___________________________________

Disadvantages
High Mold / Equipment Cost
Slow Cycle Times
Figure 15-3 Page 328

2003 Bill Young

___________________________________

Die Casting

___________________________________

Molten metal forced into mold under high pressure and held under
pressure during solidification
Advantages

___________________________________

Disadvantages

___________________________________

Fine Sections & Excellent Detail

High Mold / Equipment Cost
High Production Rates
Trapped Air (Porosity)
Excellent Surface Finishes
Good Dimensional Accuracy
Long Mold Life
Special Casting Alloys with Excellent Properties
Minimal Machining

___________________________________
___________________________________
___________________________________

Table 15-2 Page 331 (Process Overview)

2003 Bill Young

___________________________________
Types of Die Casting Dies

___________________________________
___________________________________
___________________________________
___________________________________
___________________________________
___________________________________

Figure 15-4 Page 329

2003 Bill Young

10

___________________________________

2 Types of Die Casting Machines

___________________________________

_____________ (Gooseneck) Machines

___________________________________

Lower melting point metals (Zinc,Tin, Lead Alloys)

Melting furnace part of the machine
Fast cycle times (up to 15/min)

___________________________________

1 oz to 90 lb castings

___________________________________
___________________________________
___________________________________

Figure 15-5 Page 329

2003 Bill Young

11

___________________________________

2 Types of Die Casting Machines

___________________________________

_______________ Machines

___________________________________

Higher melting point metals (Brass, Aluminum, Magnesium)

Melting furnace separate from machine
Longer cycle times

___________________________________
___________________________________
___________________________________
___________________________________

Figure 15-6 Page 330

2003 Bill Young

12

___________________________________
___________________________________

Other Multiple Use Mold Casting Processes

___________________________________
___________ Casting (Liquid-Metal Forging)

___________________________________

Centrifugal Casting (Figure 15-8)

Semicentrifugal Casting (Figure 15-11)

___________________________________

Centrifuging (Figure 15-12)

___________________________________

Continuous Casting (Figure 6-5)

___________________________________

Electromagnetic Casting

2003 Bill Young

13

___________________________________
Melting Requirements for Casting

___________________________________

The source that provides the molten metal for the casting operation should
meet the following criteria:

___________________________________
___________________________________

Provide adequate amount of material or meet required melting rate

Provide material at the necessary temperature for pouring

___________________________________

Maintain the desired chemistry and quality required

Minimize contamination

___________________________________

Hold the material without deterioration of quality

___________________________________

Economical to operate
No pollution

2003 Bill Young

14

___________________________________
___________________________________

Melting Procedure Selection

___________________________________

Factors that determine which melting procedure to use:

Temperature needed to melt and superheat the metal

___________________________________

Alloy being melted

Desired melting rate or quantity of metal

___________________________________

Desired quality of the metal

___________________________________

Availability and cost of fuel

Variety of metals or alloys to be melted

___________________________________

Batch or continuous melting

Required level of emission control
Capital and operating costs

2003 Bill Young

15

___________________________________
___________________________________

Melting Methods

___________________________________

Virtually all foundries use one of these types of furnace

___________

___________________________________

Indirect Fuel-Fired Furnaces

Air Furnaces or Direct Fuel Fired (Figure 15-14)

___________________________________

_____ Furnaces (Figures 15-15 & 15-16)

___________________________________

Induction Furnaces (Figures 15-17 & 15-18)

___________________________________

2003 Bill Young

16

___________________________________
Cleaning, Finishing, & Heat Treatment

___________________________________

Most castings require some level of secondary processing such as:

___________________________________

Removing cores

___________________________________

Removing gates and risers (trim dies, saws, torches)

Removing fins and flash (tumbling)

___________________________________

Cleaning (tumbling, shot blast)

___________________________________

Repairing defects (welding)

Heat treatments (annealing, stress relieving)

___________________________________

Inspection (liquid penetrant, x-ray, etc)

2003 Bill Young

17

___________________________________
Chapter 15 Multiple Use Mold Casting Processes

___________________________________

Difference between expendable-mold & multiple-use-mold casting

General understanding of die casting & the two basic types of machines

Basic concept of the different multiple-use-mold casting processes

___________________________________

General understanding of the different types of melting methods, what

they are used for, their advantages & disadvantages

___________________________________

General understanding of cleaning, finishing, & heat treatment of castings

___________________________________

___________________________________

___________________________________

Review Questions: __________________________________________

2003 Bill Young

18