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Lesson Outcomes
By the end of this lessons, students should be able to
explain:
1. The generic metal casting process
2. The sand casting process and example products
3. The investment casting process and example
products
4. The die casting process and example products
Types of molds
Casting processes can be classified by the type of mold used:
Expendable molds
After the casting has solidified, mold is broken to remove the
casting
Typically made of sand, plaster, ceramics
Permanent molds
Used repeatedly (not broken after solidification)
Made of metals
Composite molds
Consists of permanent and expendable portions
Made of two or more different materials (eg: sand, graphite, metal)
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Overview
Process
Shellmold
Advantages
Gooddimensionalaccuracy
andsurfacefinish;high
productionrate.
Limitations
Partsizelimited;expensive
patternsandequipmentrequired.
sand
Mostmetalscastwithnolimit
tosize;complexshapes
Patternshavelowstrengthand
canbecostlyforlowquantities
Plastermold
Intricateshapes;good
dimensionalaccuracyand
finish;lowporosity.
Limitedtononferrousmetals;
limitedsizeandvolumeof
production;moldmakingtime
relativelylong.
Ceramicmold
Intricateshapes;close
toleranceparts;goodsurface
finish.
Limitedsize.
Investment
Intricateshapes;excellent
surfacefinishandaccuracy;
almostanymetalcast.
Partsizelimited;expensive
patterns,molds,andlabor.
Permanentmold
Goodsurfacefinishand
dimensionalaccuracy;low
porosity;highproductionrate.
Highmoldcost;limitedshape
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andintricacy;notsuitablefor
highmeltingpointmetals.
Overview
Examples
(a)
(b)
Sand Casting
Most common type of casting
The mold is made of sand
There are two types of sand used:
Naturally bonding
Synthetic
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Flask
2.
Pouring basin
3.
Sprue
4.
Runner System
5.
Channels that allow metal to flow from the sprue to mold cavity
Risers
6.
Store and supply additional molten metal to the casting as it shrinks during
solidification
Cores
7.
Vents
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Investment casting
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Die Casting
In permanent-mold casting, two halves of a mold are made
from materials that resist erosion and thermal fatigue such
as cast iron, steel and graphite.
The die casting process:
A piston traps a volume of molten metal
Piston then forces molten metal into the die cavity through a
nozzle
Metal is held under pressure (up to 35 MPa) until it solidifies.
The part is then ejected by an ejector mechanism
The die is normally cooled using circulating water or oil
Example products:
Engine blocks, hand tools, motor housings
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Hot-chamber die-casting
Heated chamber
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Summary
Metal casting involves pouring molten metal into a
mold, allowing the metal to solidify and removing
the part from the mold
Casting processes can be classified as permanent
mold and expendable mold processes
Each process is suitable for manufacturing a
particular class of products.
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