METAL CASTING

PERMANENT MOLD
CASTING
o

Casting process involves pouring a molten metal

by gravity into a steel (or cast iron) mold.
Common casting metals
arealuminium,magnesium, andcopper alloys.
Others includetin,zinc, andleadalloys
andironand steel are also cast ingraphite molds.
Typical parts includegears,splines,wheels,gear
housings,pipe fittings,fuel injection housings,
and automotive enginepistons.

PROCESS
Step 1: mold is preheated and coated

Step 2: cores (if used) are inserted and

mold is closed.

Step 3: molten metal is poured into the

mold, molten metal is poured into the
mold, where it solidifies.

The permanent mold casting is similar to the

sand casting process. In distinction from sand
molds which are broken after each casting a
permanent mold may be used for pouring of
at least one thousand and up to 100,000
casting cycles.
Manufacturing metal mold is much more
expensive than manufacturing sand molds or
investment casting mold.
Ferrous and non-ferrous metals and alloys are
cast by the permanent mold casting process.

Advantages

Reusable mold, good surface finish, good

dimensional accuracy, and high production
ratesHomogeneous grain structure and
chemical composition;
Fast cooling rates created by using a metal
mold results in a finergrainstructure
Low shrinkage and gas porosity;
Good surface quality;
Low dimensions tolerances

Disadvantages

High tooling cost;

Limited to low-melting-point metals;
Short mold life;
Simpler shapes only

DIE CASTING
o

Die casting is a permanent mold casting

process in which the molten metal is
injected into the mold cavity at an
increased pressure. The mold used in the
die casting process is called a die. The
molten metal injection is carried out by a
machine called die casting machine.

Pressure is maintained during solidification,

then mold is opened and part is removed
Use of high pressure to force metal into die
cavity is what distinguishes this from other
permanent mold processes
Designed to hold and accurately close two
mold halves and keep them closed while
liquid metal is forced into cavity.

Two main types:

1. Hot-chamber machine
Metal is melted in a container, and a piston
injects liquid metal under high pressure into
the die
High production rates - 500 parts per hour
Applications limited to low melting-point
metals that do not chemically attack
plunger and other mechanical components
Casting metals: zinc, tin, lead, and
magnesium

Process

(1) with die closed and plunger

withdrawn, molten metal flows into
the chamber

(2) plunger forces metal in chamber to

flow into die, maintaining pressure
during cooling and solidification

2. Cold-chamber machine
Molten metal is poured into unheated
chamber from external melting container,
and a piston injects metal under high
pressure into die cavity
High production but not usually as fast as
hot-chamber machines
Casting metals: aluminum, brass, and
magnesium alloys

(1) with die closed and ram withdrawn,

molten metal is poured into the chamber

(2) ram forces metal to flow into die,

maintaining
pressure during cooling and solidification.

Advantages

Excellent dimensional accuracy

Smooth cast surfaces
Thinner walls can be cast
Inserts can be cast-in (such as threaded
inserts, heating elements, and high strength
bearing surfaces).
Reduces or eliminates secondary machining
operations.
Rapid production rates.
Casting of low fluidity metals.

Disadvantages

Very highcapital cost

Process is limited to high-fluidity metals
Casting weights must be between
30grams
It is only for parts in which softness is
acceptable

SHELL-MOLD CASTING

Uses aresincoveredsandto form

themold
Use both ferrous and non-ferrous metals,
most commonly using cast iron, carbon
steel, alloy steel, stainless steel,
aluminum alloys, and copper alloys.
Typical parts are small-to-medium in size
and require high accuracy, such as gear
housings, cylinder heads, connecting
rods, and lever arms.

(1) A heated pattern is placed over a

dump box containing a sand and resin
mixture.

(2) box is inverted so that sand and

resin fall onto the hot pattern,

causing a layer of the mixture to
partially cure on the surface to form a
hard shell

(3) box is repositioned so that loose

uncured particles drop away

(4) sand shell is heated in oven for

several minutes to complete curing

(5) shell mold is stripped from the
pattern

(6)Matched shells are then joined and

supported in a flask ready for pouring.

(7) the finished casting with sprue

removed

Advantages

It can be completely automated formass

production
High productivity
Low labor costs
Good surface finishes
Precision of the process

Disadvantages

Limited part size

More expensive metal pattern
Difficult to justify for small quantities

Investment Casting

Investment (lost wax) casting is an

ancient method of precision casting
complex near-net-shape details.
The investment casting process uses
expendable patterns made of
investment casting wax
It is a precision casting process castings of high accuracy and intricate
detail

PROCESS

(1) wax patterns are produced

(2) several patterns are attached to a
sprue to form a pattern tree

(3) the pattern

tree is coated
with a thin layer
of refractory
material

(4) the full mold is

formed by
covering the
coated tree with
sufficient
refractory material
to make it rigid

(5) the mold is held in

an inverted position
and heated to melt
the wax and permit it
to drip out of the
cavity

(6) the mold is preheated

to a high temperature,
which ensures that all
contaminants are
eliminated from the
mold; it also permits
the liquid metal to flow
more easily into the
detailed cavity; the
molten metal is poured;
it solidifies

(7) the mold is broken away from the

finished casting - parts are separated
from the sprue

Advantages

Many Intricate forms with undercuts can

be cast.
A very smooth surface is obtained with
no parting line.
Dimensional accuracy is good.
Certain unmachinable parts can be cast
to preplanned shape.
It may be used to replace die-casting
where short runs are involved.

Disadvantages

This process is expensive, is usually

limited to small casting, and presents
some difficulties where cores are
involved.
Investment castings require very long
production-cycle times.
This process is practically infeasible for
high-volume manufacturing, due to its
high cost and long cycle times.

PLASTER MOLD CASTING

Molding material isplaster of Paris

It can only be used with non-ferrous
materials
It is used for castings as small as 30g
(1oz) to as large as 45kg (99lb)
Thepatternis usually made from metal,
howeverrubbermolds may be used for
complex geometry

Process

The plaster is mixed and the pattern is

sprayed with a thin film of parting
compound to prevent the plaster from
sticking to the pattern.
The plaster is then poured over the
pattern and
The mold is then baked, between 120C
and 260C , to remove any excess
water.

Dried mold is then assembled,

preheated, and the metal poured.
After the metal has solidified, the plaster
is broken from the cast part.
The used plaster cannot be reused

Advantages

Good dimensional accuracy and surface

finish
Capability to make thin crosssections in
casting

Disadvantages

Moisture in plaster mold causes problems:

Mold

must be baked to remove moisture

Mold strength is lost when is over-baked, yet
moisture content can cause defects in product

Plaster molds cannot stand high

temperatures, so limited to lower melting
point alloys

Ceramic Mold Casting

Similar to plaster mold casting except that
mold is made of refractory ceramic
materials that can withstand higher
temperatures than plaster
Ceramic molding can be used to cast
steels, cast irons, and other
hightemperature alloys
Applications similar to those of plaster
mold casting except for the metals cast

Furnaces for Casting

Processes

Furnaces most commonly used in

foundries:

Cupolas
Direct fuelfired furnaces
Crucible furnaces
Electricarc furnaces
Induction furnaces

Metals for Casting

Most commercial castings are made of

alloys rather than pure metals

Alloys are generally easier to cast, and

properties of product are better

Casting alloys can be classified as:

Ferrous
Nonferrous