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MetalCastingProcesses
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page111
TABLE 11.1
Process
Summary of
Casting
Processes
Advantages
Limitations
Sand
Almostanymetalcast;nolimit
tosize,shapeorweight;low
toolingcost.
Somefinishingrequired;
somewhatcoarsefinish;wide
tolerances.
Shellmold
Gooddimensionalaccuracyand
surfacefinish;highproduction
rate.
Partsizelimited;expensive
patternsandequipment
required.
Expendablepattern
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
andintricacy;notsuitablefor
highmeltingpointmetals.
Die
Excellentdimensionalaccuracy
andsurfacefinish;high
productionrate.
Diecostishigh;partsize
limited;usuallylimitedto
nonferrousmetals;longlead
time.
Centrifugal
Largecylindricalpartswith
goodquality;highproduction
rate.
Equipmentisexpensive;part
shapelimited.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page112
Die-Casting Examples
(a)
(b)
Figure11.1(a)ThePolaroidPDC2000digitalcamerawithaAZ91Ddiecast,highpurity
magnesiumcase.(b)TwopiecePolaroidcameracasemadebythehotchamberdiecasting
process.Source:CourtesyofPolaroidCorporationandChicagoWhiteMetalCasting,Inc.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page113
Process
Typical
materials
cast
Weig ht(kg)
Minimum
Sand
All
Shell
All
Expendable
mold
pattern
All
Nonferrous
Plaster
(Al,Mg,Zn,
mold
Cu)
All
(Highmelting
Investment
pt.)
Permanent
mold
All
Nonferrous
(Al,Mg,Zn,
Die
Cu)
Centrifugal
All
Maximum
Typical
surface
finish
Porosity*
(m,Ra)
Sectionthic kness(mm)
Shape Dimensional
complexity* accuracy* Minimum
Maximum
0.05
0.05
Nolimit
100+
525
13
4
4
12
23
3
2
3
2
Nolimit
0.05
Nolimit
520
Nolimit
0.05
50+
12
12
0.005
100+
13
75
0.5
300
23
23
34
50
1
3
0.5
2
12
100
<0.05
50
12
12
34
5000+
210
12
34
*Relativerating:1best,5worst.
Note :Theseratingsareonlygeneral;significantvariationscanoccur,dependingonthemethodsused.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page114
Casting Examples
Figure 11.2 Typical grayiron castings used in
automobiles, including
transmission valve body
(left) and hub rotor with
disk-brake cylinder (front).
Source: Courtesy of Central
Foundry Division of General
Motors Corporation.
2001PrenticeHall
Page115
Figure11.4Schematicillustrationofasandmold,showingvariousfeatures.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page116
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page117
Wood
Aluminum
Rating
Steel
Plastic
Castiron
Machinability
E
G
F
G
G
Wearresistance
P
G
E
F
E
Strength
F
G
E
G
G
Weightb
E
G
P
G
P
Repairability
E
P
G
F
G
Resistanceto:
Corrosionc
E
E
P
E
P
Swellingc
P
E
E
E
E
aE,Excellent;G,good;F,fair;P,poor.
bAsafactorinoperatorfatigue.
cBywater.
Source :D.C.EkeyandW.R.Winter,IntroductiontoFoundryTechnology. NewYork.
McGrawHill,1958.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page118
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page119
Figure 11.8 Examples of sand cores showing core prints and chaplets to support cores.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1110
Squeeze Heads
Figure 11.9 Various designs
of squeeze heads for mold
making: (a) conventional flat
head; (b) profile head; (c)
equalizing squeeze pistons;
and (d) flexible diaphragm.
Source: Institute of British
Foundrymen. Used with
permission.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1111
Figure 11.10 Vertical flaskless molding. (a) Sand is squeezed between two halves of the pattern. (b)
Assembled molds pass along an assembly line for pouring.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1112
Figure 11.11 Schematic illustration of the sequence of operations for sand casting. Source: Steel
Founders' Society of America. (a) A mechanical drawing of the part is used to generate a design for the
pattern. Considerations such as part shrinkage and draft must be built into the drawing. (b-c) Patterns have
been mounted on plates equipped with pins for alignment. Note the presence of core prints designed to
hold the core in place. (d-e) Core boxes produce core halves, which are pasted together. The cores will be
used to produce the hollow area of the part shown in (a). (f) The cope half of the mold is assembled by
securing the cope pattern plate to the flask with aligning pins, and attaching inserts to form the sprue and
risers. (continued)
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1113
Figure 11.11 (g) The flask is rammed with sand and the plate and inserts are removed. (g) The drag half is
produced in a similar manner, with the pattern inserted. A bottom board is placed below the drag and aligned
with pins. (i) The pattern, flask, and bottom board are inverted, and the pattern is withdrawn, leaving the
appropriate imprint. (j) The core is set in place within the drag cavity. (k) The mold is closed by placing the cope
on top of the drag and buoyant forces in the liquid, which might lift the cope. (l) After the metal solidifies, the
casting is removed from the mold. (m) The sprue and risers are cut off and recycled and the casting is cleaned,
inspected, and heat treated (when necessary).
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1114
Figure 11.12 Surface roughness in casting and other metalworking processes. See also Figs. 22.14 and
26.4 for comparison with other manufacturing processes.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1115
Dump-Box Technique
Figure 11.13 A common
method of making shell
molds. Called dump-box
technique, the limitations are
the formation of voids in the
shell and peelback (when
sections of the shell fall off
as the pattern is raised).
Source: ASM International.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1116
Composite Molds
Figure 11.14 (a) Schematic illustration of a semipermanent composite mold. Source: Steel
Castings Handbook, 5th ed. Steel Founders' Society of America, 1980. (b) A composite
mold used in casting an aluminum-alloy torque converter. This part was previously cast in
an all-plaster mold. Source: Metals Handbook, vol. 5, 8th ed.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1117
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1118
Ceramic Molds
Figure 11.16 Sequence of operations in
making a ceramic mold. Source: Metals
Handbook, vol. 5, 8th ed.
2001PrenticeHall
Page1119
Figure 11.18
Schematic
illustration of
investment
casting, (lost-wax
process).
Castings by this
method can be
made with very
fine detail and
from a variety of
metals. Source:
Steel Founders'
Society of
America.
Investment
Casting
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1120
Figure 11.19 Investment casting of an integrally cast rotor for a gas turbine. (a) Wax pattern assembly.
(b) Ceramic shell around wax pattern. (c) Wax is melted out and the mold is filled, under a vacuum,
with molten superalloy. (d) The cast rotor, produced to net or near-net shape. Source: Howmet
Corporation.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1121
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1122
Vacuum-Casting Process
Figure 11.21 Schematic illustration of the vacuum-casting process. Note that the mold has a
bottom gate. (a) Before and (b) after immersion of the mold into the molten metal. Source: From
R. Blackburn, "Vacuum Casting Goes Commercial," Advanced Materials and Processes,
February 1990, p. 18. ASM International.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1123
Pressure Casting
Figure 11.22 (a) The bottom-pressure casting process utilizes graphite molds for the production of steel
railroad wheels. Source: The Griffin Wheel Division of Amsted Industries Incorporated. (b) Gravitypouring method of casting a railroad wheel. Note that the pouring basin also serves as a riser. Railroad
wheels can also be manufactured by forging.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1124
(b)
Figure 11.23 (a) Schematic illustration of the hot-chamber die-casting process. (b) Schematic
illustration of the cold-chamber die-casting process. Source: Courtesy of Foundry Management and
Technology.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1125
(a)
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1126
Figure 11.24 (b) 800-ton hot-chamber die-casting machine, DAM 8005 (made
in Germany in 1998). This is the largest hot-chamber machine in the world
and costs about $1.25 million.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1127
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1128
Ultimate
tensile
strength
(MPa)
Yield
strength
(MPa)
Elongation
in50mm
(%)
Aluminum380(3.5Cu8.5Si)
320
160
2.5
13(12Si)
300
150
2.5
Brass858(60Cu)
380
200
15
MagnesiumAZ91B(9Al0.7Zn)
230
160
ZincNo.3(4Al)
280
10
5(4Al1Cu)
320
Alloy
Applications
Appliances,automotivecomponents,
electricalmotorframesandhousings
Complexshapeswiththinwalls,parts
requiringstrengthatelevated
temperatures
Plumbingfiztures,lockhardware,
bushings,ornamentalcastings
Powertools,automotiveparts,sporting
goods
Automotiveparts,officeequipment,
householdutensils,buildinghardware,
toys
Appliances,automotiveparts,building
hardware,businessequipment
Source :DatafromAmericanDieCastingInstitute
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1129
2001PrenticeHall
Page1130
Semicentrifugal Casting
Figure 11.28 (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes can
be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are placed at
the periphery of the machine, and the molten metal is forced into the molds by centrifugal force.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1131
Squeeze-Casting
Figure 11.29 Sequence of operations in the squeeze-casting process. This process combines the
advantages of casting and forging.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1132
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1133
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1134
Melt Spinning
Figure 11.32 Schematic
illustration of melt-spinning to
produce thin strips of
amorphous metal.
KalpakjianSchmid
ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1135
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ManufacturingEngineeringandTechnology
2001PrenticeHall
Page1136