1.

0 INTRODUCTION

Casting is one of the earliest known methods of metal formation. This generally means
inserting liquid metal into a fireproof mold with the shape cavity you want it to make and leaving
it solid for a long time before removing it. When compacted, the desired metal object is removed
from the fire resistance either by breaking the mold or releasing the mold. The stuffed object is
called a casting. This process is also called the establishment. The casting requires a lot of
process and it includes pattern fabrication, mold construction and molten metal casting.

In the casting, the pattern is a replica of an object to be thrown, used to prepare the cavity
where the liquid material is poured during the casting process. It provides the shape for the
object to be thrown. Typically, patterns used in sand casting can be made from wood, metal,
plastic or other materials. Patterns are created according to the proper construction standards, so
they can last for a reasonable amount of time, according to the quality of the pattern they are
building, and so they will repeatedly provide acceptable dimensional cutters.

The pattern maker or drill engineer decides where the poles, gate systems, and risers are
located in relation to the pattern. Where holes are required in the casting, the core may be used
which determines the volume or location of the casting where the metal will not enter.
Sometimes the chassis can be placed on the surface of the pattern before printing, which is then
shaped into a sand mold. Chill is a heat sink that allows for quick local cooling. Rapid cooling
may be required to improve the granular structure or to determine the molten metal freezing
order poured into the mold. Because the temperatures are much cooler, and often different metals
than those that are poured, they do not stick to the breaker when the casting is cooled. The chills
can then be retrieved and reused.

Mold construction requires several criteria. The choice of mold material is based on the
nature of the processing. Generally, its properties are fire resistant, green strength, dry strength,
heat strength and permeability. Refractoriness is the ability of molding material to withstand high
temperatures of metal without causing corrosion.
 QUESTION

 Sand casting
Sand casting, also known as sand molded casting, is a metal casting process characterized by
using sand as the mold material. The term "sand casting" can also refer to an object produced via
the sand casting process. Sand castings are produced in specialized factories called foundries.
Over 60% of all metal castings are produced via sand casting process. Molds made of sand are
relatively cheap, and sufficiently refractory even for steel foundry use. In addition to the sand, a
suitable bonding agent (usually clay) is mixed or occurs with the sand. The sand is typically
contained in a system of frames or mold boxes known as a flask. The mold cavities and gate
system are created by compacting the sand around models called patterns, by carving directly
into the sand, or by 3D printing

 Die casting
Die casting is a metal casting process that is characterized by forcing molten metal under high
pressure into a mould cavity. The mould cavity is created using two hardened tool steel dies
which have been machined into shape and work similarly to an injection mould during the
process. Most die castings are made from non-ferrous metals, specifically zinc, copper,
aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal
being cast, a hot- or cold-chamber machine is used. The casting equipment and the metal dies
represent large capital costs and this tends to limit the process to high-volume production.

 Shell mould casting

Shell moulding, also known as shell-mould casting, is an expendable mould casting process that
uses resin covered sand to form the mould. As compared to sand casting, this process has
better dimensional accuracy, a higher productivity rate, and lower labour requirements. It is
used for small to medium parts that require high precision. Shell mould casting is a metal
casting process similar to sand casting, in that molten metal is poured into an expendable
mould. However, in shell mould casting, the mould is a thin-walled shell created from applying
a sand-resin mixture around a pattern. The pattern, a metal piece in the shape of the desired
part, is reused to form multiple shell moulds.

 Lost wax casting

Lost-wax is the process by which a duplicate metal sculpture (often silver, gold, brass or bronze)
is cast from an original sculpture. Intricate works can be achieved by this method. The steps
used in casting small bronze sculptures are fairly standardized, though the process today varies
from foundry to foundry. (In modern industrial use, the process is called investment casting.)
Variations of the process include: "lost mould", which recognizes that materials other than wax
can be used (such as: tallow, resin, tar, and textile) and "waste wax process" (or "waste mould
casting"), because the mould is destroyed to remove the cast item.
A. Compare the above casting processes and place them in order from best to
worst in the ability to make complex shape.

CASTING PROCESS EXPLAINATION

Sand Casting  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.
 A low cost for post-casting tooling.
Die Casting  High-speed production.
 Dimensional accuracy and stability
 Strength and weight
 Multiple finishing techniques
 Simplified Assembly
Shell Mould Casting  Good surface quality.
 High rough casting dimensional accuracy.
 Thin wall thickness and complex castings.
 Less manpower and molding skill requirements.
 High production costs and casting prices.
 High pattern costs.
 Size and weight limitation
Lost Wet Casting  The process is especially advantages for high-melting-
point alloys as well as for difficult-to-machine metals.
 It is most suitable for producing small castings having
intricate shapes.
 It produces very smooth surfaces.
 It eliminates most of machining operations.
 It is applicable to all low to high-melting-point metals and
alloys.

- From the comparison of the casting process:

lost wax casting - die casting - shell mould casting - sand casting.
B. Similarly, order the above casting processes from best to worst in terms of surface
finish.

Lost wax casting - shell mould casting - die casting - sand casting

C. Figure below shows candle holders made from brass. What is the most suitable
process to manufacture them if they are needed in large quantity? Why?

Brass, alloy of copper and zinc, of historical and enduring importance because of its
hardness and workability. The earliest brass, called calamine brass, dates to Neolithic
times. It was probably made by reduction of mixtures of zinc ores and copper ores. In
ancient documents, such as the Bible, the term brass is often used to denote bronze, the
alloy of copper with tin. The most suitable process to manufacture the candle holders
that made from brass is die casting because metal die casting process has a short cycle
time. Metal flow is faster in die casting due to existence of external force. Moulds in die
casting are not as thick as those used in the sand casting or investment casting
processes.