Casting Design Modifications

CHAPTER 12

Metal Casting: Design, Materials, and

Figure 12.1 Suggested design
Economics modifications to avoid defects
in castings. Note that sharp
corners are avoided to reduce
stress concentrations.

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Casting Cross-Sections Avoiding Shrinkage Cavities

Figure 12.3 Examples of

design modifications to avoid
shrinkage cavities in castings.
Source: Steel Castings
Handbook, 5th ed. Steel
Founders' Society of America,
1980. Used with permission.

Figure 12.2 Examples of designs showing the importance of maintaining uniform cross- sections in
castings to avoid hot spots and shrinkage cavities.

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Normal Shrinkage Allowance for Some Metals

Chills
Cast in Sand Molds

Figure 12.4 The use of TABLE 12.1

metal padding (chills) to
increase the rate of cooling Metal Percent
in thick regions in a casting
to avoid shrinkage cavities. Gray cast iron 0.83–1.3
Source: Steel Castings White cast iron 2.1
Handbook, 5th ed. Steel
Founders' Society of Malleable cast iron 0.78–1.0
America, 1980. Used with Aluminum alloys 1.3
permission.
Magnesium alloys 1.3
Yellow brass 1.3–1.6
Phosphor bronze 1.0–1.6
Aluminum bronze 2.1
High-manganese steel 2.6

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 Figure 12.6
Examples of
casting design
Parting Line modifications.
Source: Steel
Casting
Handbook, 5th
Figure 12.5 Redesign of a ed. Steel
casting by making the parting Founders'
line straight to avoid defects. Society of
Source: Steel Casting America, 1980.
Handbook, 5th ed. Steel Used with
Founders' Society of America, permission.
1980. Used with permission. Casting Design
Modifications

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Desirable and Undesirable Die-Casting Mechanical Properties for Various Groups of

Practices Cast Alloys
Figure 12.7 Examples of
undesirable and desirable design
practices for die-cast parts. Note
that section-thickness uniformity is
maintained throughout the part.
Source: American Die Casting
Institute.

Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little
ductility and toughness, compared with most other cast alloys, some of which undergo considerable
elongation and reduction of area in tension. Note also that even within the same group, the properties of
cast alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of
America.

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Mechanical Properties for Various Groups of

Cast Alloys (cont.) Typical Applications for Casting and Casting
Characteristics
TABLE 12.2
Type of alloy Application Castability* Weldability* Machinability*
Aluminum Pistons, clutch housings, intake E F G–E
manifolds
Copper Pumps, valves, gear blanks, F–G F F–G
marine propellers
Ductile iron Crankshafts, heavy-duty gears G D G
Gray iron Engine blocks, gears, brake disks E D G
and drums, machine bases
Magnesium Crankcase, transmission housings G–E G E
Malleable iron Farm and construction machinery, G D G
heavy-duty bearings, railroad
rolling stock
Nickel Gas turbine blades, pump and F F F
valve components for chemical
plants
Steel (carbon and Die blocks, heavy-duty gear F E F
low alloy) blanks, aircraft undercarriage
members, rail-road wheels
Steel (high alloy) Gas turbine housings, pump and F E F
valve components, rock crusher
jaws
Figure 12.8 Mechanical properties for various groups of cast alloys. Note that gray iron has very little White iron Mill liners, shot blasting nozzles, G VP VP
ductility and toughness, compared with most other cast alloys, some of which undergo considerable railroad brake shoes, crushers and
elongation and reduction of area in tension. Note also that even within the same group, the properties of pulverizers
cast alloys vary over a wide range, particularly for cast steels. Source: Steel Founders' Society of Zinc Door handles, radiator grills, E D E
America. *E, excellent; G, good; F, fair; VP, very poor; D, difficult.

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 Properties and Typical Applications of Cast Irons Mechanical Properties of Gray Cast Irons

TABLE 12.3
Ultimate TABLE 12.4
tensile Yield Elongation
strength strength in 50 mm Ultimate
Cast iron Type (MPa) (MPa) (%) Typical applications tensile Compressive Elastic
Gray Ferritic 170 140 0.4 Pipe, sanitary ware ASTM strength strength modulus Hardness
Pearlitic 275 240 0.4 Engine blocks, machine tools class (MPa) (MPa) (GPa) (HB)
Martensitic 550 550 0 Wearing surfaces
Ductile Ferritic 415 275 18 Pipe, general service 20 152 572 66 to 97 156
(Nodular) Pearlitic 550 380 6 Crankshafts, highly stressed parts 25 179 669 79 to 102 174
Tempered 825 620 2 High-strength machine parts,wear-resistant 30 214 752 90 to 113 210
martensite parts
35 252 855 100 to 119 212
Malleable Ferritic 365 240 18 Hardware, pipe fittings, general engineering
service 40 293 965 110 to 138 235
Pearlitic 450 310 10 Railroad equipment, couplings 50 362 1130 130 to 157 262
Tempered 700 550 2 Railroad equipment, gears, connecting rods 60 431 1293 141 to 162 302
martensite
White Pearlitic 275 275 0 Wear-resistant parts, mill rolls

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Properties and Typical Applications of Cast

Nonferrous Alloys General Cost Characteristics of Casting
TABLE 12.5 Processes
Ultimate
tensile Yield Elongation
strength strength in 50 mm
Alloys (UNS) Condition (MPa) (MPa) (%) Typical applications TABLE 12.6
Aluminum alloys Sand castings Cost*
195 (AO1950) Heat treated 220–280 110–220 8.5–2 Sand castings Production
319 (AO3190) Heat treated 185–250 125–180 2–1.5 Permanent mold castings Process Die Equipment Labor rate (Pc/hr)
356 (AO3560) Heat treated 260 185 5
Copper alloys
Sand L L L–M <20
Red brass (C83600) Annealed 235 115 25 Pipe fittings, gears Shell-mold L–M M-H L–M <50
Yellow brass (C86400) Annealed 275 95 25 Hardware, ornamental Plaster L–M M M–H <10
Manganese bronze Annealed 480 195 30 Propeller hubs, blades Investment M–H L-M H <1000
(C86100) Permanent mold M M L–M <60
Leaded tin bronze Annealed 260 105 35 Gears, bearings, valves Die H H L–M <200
(C92500)
Centrifugal M H L–M <50
Gun metal (C90500) Annealed 275 105 30 Pump parts, fittings
Nickel silver (C97600) Annealed 275 175 15 Marine parts, valves * L, low; M, medium; H, high.
Magnesium alloys
AZ91A F 230 150 3 Die castings
AZ63A T4 275 95 12 Sand and permanent mold
castings
AZ91C T6 275 130 5 High strength
EZ33A T5 160 110 3 Elevated temperature
HK31A T6 210 105 8 Elevated temperature
QE22A T6 275 205 4 Highest strength

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