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CASTING TECHNIQUES,[object Object],Ms. Sumbal,[object Object]
INTRODUCTION,[object Object],Basically casting involves the introduction of molten metal into a mold cavity; upon solidification the metal takes the shape of the cavity.,[object Object],Almost all metals can be cast in the final shape desired, often with only minor finishing required.,[object Object]
INTRODUCTION,[object Object],Casting process is the most economical process of going from raw material to final product.,[object Object],It should be the first choice for primary process selection.,[object Object],Other processes should be selected only when casting cannot meet the desired design requirements.,[object Object]
Metallurgy  Casting
ENGINE BLOCK & CYLINDER HEAD,[object Object]
INTRODUCTION,[object Object],The objective is to produce castings that are,[object Object],free from defects &,[object Object],that meet requirements for strength, dimensional accuracy, & surface finish.,[object Object]
ADVANTAGES,[object Object],COMPLICATIONS OF SHAPE: this is the only method that can produce complex, 3-d internal & external surfaces simultaneously. ,[object Object],PRODUCT SIZE:  very large, bulky products are difficult to manufacture using other processes.,[object Object],PROPERTIES:  The properties of the product is isotropic or non-directional,[object Object]
SHAPES,[object Object],Casting is an efficient process for producing intricate shapes in a single piece, including shapes with internal cavities,[object Object],Products may range in sizes from a few millimeters with weights of a few grams, to very large pieces weighing as much as 300 tons. ,[object Object]
Metallurgy  Casting
ADVANTAGES,[object Object],ALLOY PROPERTIES:  The alloy may be suitable only for casting.,[object Object],ECONOMICS: the process is economical for low production & high production rates.,[object Object]
CASTING PROCESS,[object Object],The basic steps in making sand castings: ,[object Object],Patternmaking ,[object Object],Core making ,[object Object],Molding ,[object Object],Melting and pouring ,[object Object],Cleaning,[object Object]
CASTING PROCESS,[object Object],The pattern is the replica of the object to be cast. It is usually made of wood or metal or sand.,[object Object],It is made in two halves which have to be fitted together using dowel pins.,[object Object]
CASTING PROCESS,[object Object]
CASTING PROCESS,[object Object]
CASTING PROCESS,[object Object]
IMPORTANT FACTORS,[object Object],Solidification of metal  from its molten state (which is usually accompanied by shrinkage),[object Object],Flow of molten metal into the mold cavity. (gating system),[object Object],Heat transfer/cooling rate during solidification & cooling of the metal in the mold. (cast structure),[object Object],Mold material & its influence on the casting process.,[object Object]
Casting processes are generally classified according to,[object Object],the mold materials, ,[object Object],molding processes & ,[object Object],methods of feeding metal.,[object Object]
PROBLEM,[object Object],Three pieces of casting have the same volume but different shapes. One is a sphere, one a cube, & other a cylinder with height equal to its diameter. Which one will solidify the fastest?,[object Object],Ans. Solidification time= C(Vol/surface area)2,[object Object]
SHRINKAGE & POROSITY,[object Object],Contraction of liquid metal as it cools.,[object Object],Contraction due to latent heat of fusion as it cools (solidification),[object Object],Contraction of the solidified metal as its temperature drops to room temperature. ,[object Object]
Metallurgy  Casting
Metallurgy  Casting
POROSITY,[object Object],The most undesirable effect of shrinkage is porosity.,[object Object],When the liquid is unable to reach the regions where solidification is occurring, porosity develops due to shrinkage of solidified metal.,[object Object],Casting must provide for an adequate supply of liquid metal so that this porosity during cooling/solidification can be avoided. ,[object Object]

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Metallurgy Casting

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