Introduction

Foundry Engineering deals with the process of making casting in moulds prepared by patterns Stages:
1. 2. 3. 4. 5. Pattern making Moulding and core making Melting and casting Fettling Testing and inspection

Foundry Hand Tools

Foundry Hand Tools

Foundry Hand Tools

Foundry Hand Tools

Foundry Hand Tools - LADLES

Foundry Hand Tools- CRUCIBLES

Melting Equipments
In order to obtain the proper pouring and melting temperature of the metal several furnaces are used: For ferrous metals:
Cupola furnaces Open heart furnaces Electric furnaces

For non-ferrous metals:

Pit Type Stationary type Tilting Type

Cupola
Used for melting for cast iron. Low cost. Better control of temp and chemical composition. Easy tapping. Consumes easily available fuels.

Electric Furnace
High Temp. Fast Melting. Controlled atm. For large quantities. High cost and maintenance. Fumes, smoke and noise.

Oil / Gas fired Rotary Furnace

Moulding
Mould is a void or cavity created in a compact sand mass with the help of pattern. Core is a sand shape exactly similar to the cavities to be produced in casting. Generally made differently in a core box. Permanent moulds are made up of ferrous metals and alloys, normally used for casting of low melting point material, costly Temporary refractory moulds are made of refractory sands and resin, for high melting points and bigger objects, Cheap.

Main constituents of Moulding sand

Principle Constituents: Silica Sand
Major Portion, 80-82 % High Softening Temperature and thermal Stability, chemical resistively and permeability. Found in banks and bottom of rivers.

Binders
Imparts sufficient strength and cohesiveness, but decreases permeability of sand. Organic, in-organic and Clay are used.

Additives Water

Additives of Moulding sand

Additives of Moulding sand

Sand Grains

Properties of Moulding Sand

Porosity or Permeability Flowability or Plasticity Refractoriness Adhesiveness Cohesiveness Collapsibility Durability Fitness Bench life Co-efficient of expansion Chemically Neutral Reusable, Cheap and Easily available

Classification of Moulding Sand

Special Sand

Special Sand

Special Sand

Preparation Moulding Sand

Sand Testing

Moulding Process
According to the method Used: 1. Floor Moulding Foundry floor acts as drag and may be covered with cope or may be casted open. Used for all medium and large casting 2. Bench Moulding For small and light moulds Done in cope and drag 3. Pit Moulding Moulding for extremely large casting is done in pit Pit acts as drag and separate cope can be used to make gates and runners

Moulding Process
4. Machine Moulding All the jobs of ramming, moulding and gate making, drawing of pattern is done by machines. Produces identical and consistent castings Preferred for the mass production

Moulding Process

Moulding Process

Moulding Process

Moulding Process

Gating System
Gating System means all the passages through which the molten metal enters the mould cavity. Includes: Pouring basin Runner Gate Riser It has great impact upon the quality of the casting produced.

Requirement of Gating System

Low flow velocity of molten metal. Insure complete filling of cavity. Prevent absorption of moisture while flow. Prevent formation of oxides. Prevent entry of slag, dross etc. Assist directional solidification. Should be practical and economical.

Types of Gates
1. 2. 3. 4. Top Gate Bottom Gate Parting Gate Step Gate

Types of Gates

Special Casting Processes

Gravity Die or Permanent Mould Casting

Molten metal is poured under gravity only. Uses permanent moulds; can be reused many times Made of grey cast iron; inner surface coated with refractories. Made in two halves with built-in gating system.

Centrifugal Casting
Mould is rotated rapidly about its central axis as the metal is pored into it. Centrifugal force plays major role in shaping and feeding of the casting. C.F. helps to distribute the molten metal evenly to all surfaces and separates the slag from out flowing molten metal. Three types:
1. True Centrifugal 2. Semi Centrifugal 3. Centrifuge

True Centrifugal Casting

True Centrifugal Casting

Semi Centrifugal and Centrifuge Casting

Carbon dioxide Moulding

This process is basically a hardening process for the moulds and cores. As Co2 gas is passed through a sand mixture containing sodium silicate, the sand immediately becomes extremely strong bonded as sodium silicate becomes a stiff gel giving the necessary strength to the mould. Pure dry silica is mixed with 3-5% sodium silicate and water; and is rammed in the moulding box. Co2 is forced into mould at high pressure. Additional hardening may be done by baking.

Carbon dioxide Moulding

Carbon dioxide Moulding

Shell Moulding
The sand mixed with thermosetting resign is allowed to come into contact with heated metallic pattern plate. A thin and strong shell of mould is formed around the pattern. The shell is removed from the pattern and paced in cope and drag with backing material and molten metal is poured for casting.

Shell Moulding

Rotational Shell Moulding

Shell Moulding

Casting Defects

Casting Defects
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Blow holes Porosity Shrinkage Hot tears Drop Metal Penetration Fusion Shot metal Shift Swells Hard Spots Warpage

Casting Defects

Casting Defects

Casting Defects

Casting Defects

Casting Defects

Casting Defects

Cleaning of Casting (Fettling)

After casting has solidified it is removed form the mould and is cleaned to remove the runner risers cores etc. 1. Rough Cleaning 2. Surface cleaning
Wire brush Sand blasting Shot Blasting

3. Finishing 4. Inspection of casting

Destructive and Non-Destructive

Inspection of casting
Destructive Cutting samples and examining properties Tensile, Compression and Torsion Testing Non-Destructive Visual Inspection Dimensional Inspection Pressure Testing Radiographic Inspection Magnetic Inspection