Molding by shell , die & investment casting

By

P Santosh kumar -08120033 Ankush kumar-08120009 K Sandeep-08120021

Metallurgy 6th semester

Shell molding
Casting process in which the mold is a thin shell (typically 3/8 inch) made of sand held together by a thermosetting binder (risen). The process of creating a shell mold : Fine silica sand ,covered in a thin (36%) thermosetting resin and liquid catalyst is dumped, blown, or shot onto a hot pattern. The pattern made of cast iron is heated to 230 to 315 C (450 to 600 F). The sand is allowed to sit on the pattern for a few minutes to allow the sand to partially cure. The pattern and shell together are placed in an oven to finish curing the sand. The hardened shell is then stripped from the pattern. For casting the shell mold is placed inside a flask and surrounded with shot, sand, or gravel to reinforce the shell.

The machine that is used for this process is called a shell molding machine. It heats the pattern, applies the sand mixture, and bakes the shell.

Advantages:

Higher production rate than sand casting High dimensional accuracy and smooth finish Amenable towards automation Thin sections can be cast

Limitations: Requires expensive metal patterns resin adds to cost part size is limited Highly complicated cannot be made

Common metals:
Cast irons, casting alloys of aluminum and copper

Permanent Mold casting / Gravity Die casting

In gravity die casting, the metal is poured into the mold using only the force of gravity. The mold is typically a two piece mold clamped solidly together.

Permanent Mold Materials:

Fine grained grey cast iron

Alloy steels for large volumes and large parts Graphite for small volume castings of Al & Mg The die life depends on The melting temperature of metals & alloys The molds are coated with refractory to a layer of 8 mm

Materials normally cast in permanent molds Al. alloys Mg alloys Zn alloys Grey Cast Iron

Advantages of Gravity Die Casting

A fine grained casting with superior mechanical properties

Good surface finish (4 microns) Good dimensional tolerance Mass production of castings possible Limitations Maximum weight of casting limited to 15 kg Complicated shapes cannot be produces

Applications Automobile pistons, stators, gear blanks, connecting rods etc

Cast products

Pressure Die Casting

The basic idea is to force metal into a permanent mold using high pressure. The metal then cools (often assisted by water cooling of the die). The mold is then opened, and the casting is ejected.

Constructed of alloy steel in two pieces (called the cover and the ejector). The die must withstand high temperature and pressure, so the die is typically made for chromium or tungsten steel alloys.

Molten metal enters the die cavity at pressures 70 to 2000 times the normal atmospheric pressure

Employment of high pressure aids in die casting of Narrow sections Complex shapes Finer surface details

Die Casting Machines are basically of two types

Cold Chamber die casting

Hot chamber die casting

Hot chamber machines are: -good for low temperature zinc alloys (approx. 400C) - cycle times must be short to minimize metal contamination - metal starts in a heated cylinder - a piston forces metal into the die - the piston retracts, and draws metal in Cold chamber machines: - casts high melting point metals (>600C) - high pressures used - metal is heated in a separate crucible - metal is ladled into a cold chamber - the metal is rapidly forced into the mold before it cools

Horizontal Type

Cold chamber die casting suitable for casting of Mg alloys Brass Aluminum alloy Pressure applied in cold chamber die casting method can be as high as 2000 atmospheres

Advantages

high temperature metals and alloys can be cast

large parts (weighing around 25 kgs) can be cast high surface finish ( 1 m) and dimensional tolerance better mechanical properties of the casting because of the fine grains

Limitations large cycle time

metal sometimes looses the superheat and cause defects such as cold shut dies and the machines are expensive

Applications: - automotive parts - appliances - office machines - bathroom fixtures - outboard motors

Hot Chamber Die Casting

Die closed and plunger withdrawn Metal forced into die cavity at fixed press. Plunger withdrawn & die opened

Press. 50 to 150 atm

Advantages of Hot Chamber Die Casting Improved productivity

Superior surface finish High tolerance Intricate shapes with thin walls can be easily produced

Limitations
Only low melting alloys (such as Zn, Sn, Pb) are cast
Small castings weighing less than 4.5 kg can be cast

INVEST MENT CASTING

Steps followed in Investment Casting Process

1. A heat disposable pattern made of wax or plastic is made

2. A pattern assembly (tree / cluster) is prepared attached to a central wax sprue 3. Pattern assembly is invested into a ceramic slurry composed of silica flour suspended in soln. of ethylsilicate. Ceramic shell of 6mm thickness is formed around the wax assembly. 4. The assembly baked in oven to melt out the wax/plastic thereby the dimensions of mold cavity precisely match those of the product 5. The shell mold is fired at 900 to 10000 C to remove all traces of wax and also the strength gets enhanced 6. Molten metal is poured when the mold is still hot resulting in a production of a cluster of castings at a time

Applications of Investment Casting

Intricate shaped objects like jewelry Cylinder heads cam shafts gas turbine blades

Advantages of Investment Casting Process Complicated and intricate shaped products can be easily cast High dimensional tolerance achievable Surface finish is excellent Additional machining not required as it is a net shape process All types of metals and alloys can be cast by this process

Common metals: Mainly aluminum, copper and steel; also used with stainless steel, nickel, magnesium and precious metals Limitations

Size of the casting is limited (max. around 5 kg) A relatively expensive process

By

P Santosh kumar Ankush kumar K Sandeep