Casting Processes Casting Processes: ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2006

Casting Processes
ver. 2
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2006
Types of Parts Made

Engine blocks Pipes Jewelry Fire hydrants Fi h d t
Complex, 3-D Complex 3 D shapes

Near net shape p Low scrap Relatively quick process Intricate shapes Large hollow shapes No limit to size Reasonable to good surface finish
Processes
Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification Slush Continuous
Metals processed by casting

Sand casting 60% Investment casting 7% g Die casting 9% Permanent mold casting 11% Centrifugal casting 7% Shell mold casting 6%
Breakdown of Castings
Ingots for bulk deformation processing 85% Cast to near net shape - 15%
Ingots
Iron or steel molds Water-cooled molds Water cooled Continuous casting
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton
Shapes
Permanent mold (cavity)
die casting hot chamber cold chamber ld h b
Expendable Molds
sand shell slurry investment
lost wax lost foam
Shapes
Centrifugal
pipes spinning
Capabilities
Dimensions
sand casting - as large as you like small - 1 mm or so
Tolerances
0 005 in to 0 1 in 0.005 0.1
Surface finish
di casting 8 16 micro-inches (1 3 m) die ti 8-16 i i h (1-3 ) sand casting - 500 micro-inches (10-25 m)
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Casting Steps
quick route from raw material to finished product
Melt metals Pour / force liquid into hollow cavity (mold) Cool / Solidify Remove Finish
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Melting
Raw material (charge)
scrap alloying materials scrap,
Heat
Furnace Atmosphere
Atmosphere Heating
Raw materials
Air (oxygen), vacuum inert gas (argon) (oxygen) vacuum, External - electric gas oil electric, gas, Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with iron mix
Furnace material
refractory ceramics
12
Furnaces
Blast furnace
Basic Oxygen Furnace

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Furnaces
Electric Arc Furnace
Oxygen-Fuel, Oxygen Lance Furnace

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Furnaces
Induction Furnace
Electric Furnace
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Sand Casting g
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Sand Casting
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Sand Casting
18
Sand Casting Steps
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20
Sand Cast Parts
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Permanent Mold Casting
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Low Pressure Casting
23
Die Casting ( g p g (high pressure) )
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Die Casting Machine
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Die Casting
Cold chamber
Hot chamber
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Die Casting Part Example
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Continuous Casting
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29
30
31
Investment Casting C ti
32
Investment (top) and Conventional Castings
33
Lost Foam Casting
34
Lost Foam Castings
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Centrifugal Casting
horizontal
sand-lined mold g casting

vertical
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Centrifugal Casting
37
Pipe Casting Process
38
Squeeze Casting
39
Directional Solidification
40
Vacuum Casting
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Casting Characteristics
Table 5.6 Typical materials cast
All All
Weig ht (kg)
Process
Sand Shell Expendable E pendable mold pattern
Minimum
0.05 0.05
Maximum
No limit 100+
Typical surface finish (micron, Ra)

5-25 1-3
Section thickness (mm) Shape complexity Dimensional * accuracy*

1-2 2-3 3 2
Porosity*
4 4
Minimum
3 2
Maximum
No limit --
All Nonferrou Plaster s (Al, Mg, mold Zn, Cu) All (High melting Investment pt.) Permanent mold All Nonferrou s (Al Mg (Al, Mg, Die Zn, Cu) Centrifugal All
0.05
No limit
5-20
No limit
0.05
50+
1-2
1-2
--
0.005 0.5
100+ 300
1-3 2-3
3 2-3
1 3-4
1 1
1 2
75 50
<0.05 50 1-2 1-2 3-4 1 -5000+ 2-10 1-2 3-4 3 *Relative rating: 1 best, 5 worst. Note : These ratings are only general; significant variations can occur, depending on the methods used.
0.5 2
12 100
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Microstructure
43
Microstructure - Dendrites
Finer structure at walls Grains / dendrites grow to center

44
Grains on Willie Bs head Bs
45
Microstructure - Dendrites
46
Fluidity
47
Casting Defects - Porosity
48
Casting Defects
49
Shrinkage
TABLE 5.1 Volumetric solidification contraction (%) 6.6 6.3 3.8 2.53 4 4.9 Volumetric solidification contraction (%) 4.5 4 Expansion to 2.5 4.2 45.5 6.5
Metal or alloy Aluminum Al4.5%Cu Al12%Si Carbon steel 1% carbon steel Copper Source: After R. A. Flinn.
Metal or alloy 70%Cu30%Zn 90%Cu10%Al Gray iron g Magnesium White iron Zinc
50
Differential Cooling
Transition between thicker and thinner sections can lead to porosity p y
51
Pipe Defect
D t shrinkage giving rise t Due to h i k i i i to a funnel-like cavity Solutions
insulate top (glass wool) heat top (exothermic mixture thermit)
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Defects - Hot Tears
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Chills
54
Design Rules Summary

Uniform wall thickness Flat parting lines Gradual thickness transitions D ft for removal Draft f l
tapers: 0.5 to 2 degrees
Surface of mold gives surface of part

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Sand Casting Rules
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Casting costs
TABLE 5.10 Cost Cost* Process Die Sand L Shell-mold LM Plaster LM Investment MH Permanent mold M Die H Centrifugal M *L l L, low; M medium; H hi h M, di H, high. Equipment L M-H M L-M M H H Labor L M LM LM MH H LM LM LM Production rate (Pc/hr) <20 20 <50 <10 <1000 <60 <200 <50
57
Process economics
58
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Casting Processes Casting Processes: ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2006

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Casting Processes Casting Processes: ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2006

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Casting Processes

Types of Parts Made

Complex, 3-D Complex 3 D shapes

Metals processed by casting

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton

ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton

Basic Oxygen Furnace

Electric Arc Furnace

Oxygen-Fuel, Oxygen Lance Furnace

Sand Casting Steps

Sand Cast Parts

Permanent Mold Casting

Low Pressure Casting

Die Casting ( g p g (high pressure) )

Die Casting Machine

Die Casting Part Example

Investment (top) and Conventional Castings

Lost Foam Casting

Lost Foam Castings

sand-lined mold g casting

Pipe Casting Process

Typical surface finish (micron, Ra)

Section thickness (mm) Shape complexity Dimensional * accuracy*

Finer structure at walls Grains / dendrites grow to center

Grains on Willie Bs head Bs

Casting Defects - Porosity

Defects - Hot Tears

Design Rules Summary

Surface of mold gives surface of part

Sand Casting Rules

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