Casting

What is Casting and Molding

The process in which the molten material is poured

into a cavity of some shape (the part shape) and

produces a product that is in the final (or close to the
final) shape upon cooling and solidification.

Open vs. Closed Mold

Cooling curve for a pure metal during casting

A pure metal solidifies at a constant temperature equal to its freezing

point (same as melting point)

Alloys solidify over a range of temperatures

Importance of Casting and Molding

Can create parts with complex geometries
Can create both external and internal shapes
Can produce very large, massive parts
Can produce parts to net shape or near net shape
Can produce parts from materials that may be difficult to process

otherwise
May be more economical and/or suitable for mass production
.

Limitations of Casting and Molding

Limitation on mechanical properties
Porosity
Poor surface finish for some processes
Poor dimensional accuracy for some processes
Safety hazards to humans
Environmental concerns
..

Parts Made by Casting

Big parts: engine blocks and heads for automotive

vehicles, wood burning stoves, machine frames,

railway wheels, pipes, church bells, big statues, and
pump housings
Small parts: dental crowns, jewelry, small statues,
and frying pans
All varieties of metals can be cast, ferrous and
nonferrous

Important Factors in Casting

Solidification from molten state and shrinkage

(before, during and after solidification)

Flow of the molten metal into the mold cavity.
Heat transfer during solidification and cooling
Mold material and its influence on the casting
operation.
Removal of casting from mold
Need for secondary processes: machining,
grinding, etc.

Solidification time

FIGURE
Solidified skin on a steel casting; the remaining
molten metal is poured out at the times indicated in the
figure. Hollow ornamental and decorative objects are made
by a process called slush casting, which is based on this
principle. Source: After H.F. Taylor, J. Wulff, and M.C.
Flemings.

Class Practice 1 (see notes)

Example 5.3:

solidification times for various solid shapes

Two Categories of Casting Process

1. Expendable mold processes uses an expendable

mold which must be destroyed to remove casting

Mold materials: sand, plaster, and similar materials,

plus binders

2. Permanent mold processes uses a permanent

mold which can be used many times to produce many

castings
Made of metal (or, less commonly, a ceramic refractory

material)

Video Demo
https://www.youtube.com/watch?v=UVGmsS-7tIE
https://www.youtube.com/watch?v=9g_JfhjcBAU

Sand Casting Components

RE 5.10 Schematic illustration of a typical sand mold showing various features.

Important principles (see notes)

Bernoullis theorem
Mass continuity