Foundry Engineering

part 2
dr in. Dawid Myszka

Base casting processes

Sand casting process

Investment casting process
Gravity die casting process

Preasure casting process

Special casting methods

Special casting methods

Directional casting
Backpressure casting
Centrifugal casting
Metallic foams

Thixotropic casting
Casting of composites
Continuous casting

Directional casting

Equiaxed crystal
stucture

Column
structure

Single-crystal
structure

Directional casting

Directional casting

Nickel-based casting alloys

Additionaly 6 wt.% rhenium content,

relatively high refractory element level
(W+Ta + Re+Mo), and low level of
chromium employment

Backpressure casting

Centrifugal casting

Mould

Metallic foams

Metallic foams

Metallic foams
Load

Metallic foams

Metallic foams

Metallic foams

Thixotropic casting

Alloy I

Alloy II

Range of
temperatures
for tixotropic
casting

Thixotropic castings

Casting of composites

Casting of composites

Casting of composites

Casting of composites

Casting of composites

Casting of composites

Casting of composites

Continous casting

Continous casting

Continous casting

Continous casting

film

Main elements of mould

Main elements of gating system

Main elements of gating system

SIDE RISER (blind-type)

TOP RISER (open-type)

Casting cavity

Main elements of gating system

Main elements of gating system

Scheme of filing the mould

by liquid metal

Main elements of gating system

Low preasure area

Refined liquid metal stream

Sprue base

Main elements of gating system

Produkcja odleww na wiecie

Solidification

Solidification

Crystalisation

a) Columnar crystals
b) Dendritic crystals
c) Equiaxed crystals

mould
liquid

mould

liquid
Crystalisation

Smooth-walled

Wall-harshly

cristalisation

cristalisation

mould
liquid

mould
liquid

Volumetric

Mixed

cristalisation

cristalisation

Solidification

Schematic metal contraction

during solidification:
a) liquid,
b) contraction of sigle
crystals appearing moment,

c) contraction durig
solidification,

d) contraction in solid state.

Solidification

Shrink cavity

Solidification

1.
2.
3.
4.
5.

Casting
Riser
Shrink cavity
Solidified layers
Cutting line

Solidification

Partitioning of casting shape

Modulus calculation
volume
field area

Solidification

film

Solidification

Amount of alloying element B [%]

Time [s]

Solidification

Solidification

Solidification

Amount of Carbon, %

 Cast metals
Heat treatment of castings

Cast Iron

Cast Iron

Petal of graphite

Branched crystal
of graphite

Gray Iron

Ductile Iron

Steel castings

Aluminium alloys

Magnesium alloys

Steel casting
heat treatment

Steel casting heat treatment

Cast iron heat treatment

Cast iron heat treatment

Ferrite and austenite matrix

Martensitic matrix

Cementite, ferrite and austenite matrix

Ferrite and carbides matrix

Ductile iron heat treatment

Unit of Weigth/
Unit of Yield Strength