• Type of metal.

• Number of castings required.

• Shape & size of castings.
• Dimensional accuracy required.
• Casting finish required.
• Economics.
• The number of finishing operations-the
processes that provide the “closest dimensions,
best surface finish, & the most intricate detail”
usually require the smallest number of finishing
operations.
 The investment-casting process, also called
the lost-wax process, was first used during the
period 4000-3500 B.C.
 The pattern is made of wax or a plastic.
 The pattern is made by injecting molten wax or
plastic into a metal die in the shape of the object.
 All metals can be casted in investment
process.
 Applications: Jeweller, surgical instruments,
vanes and blades of gas turbine, and bolts and
triggers for fire arms.
 Advantages:
– Capability to cast parts with great complexity and
intricacy.
– Close dimensional control ( 0.076 m tolerance).
– Good surface finish.
– Wax can be recovered and reuse.
– Additional machining normally not required.

 Disadvantages:
– Normally used for smaller parts.
– Relatively expensive.
 The shell casting process, also called the Dump
box process, is the process in which dry and fine
sand mixed with resin is allowed to come into
contact with heated metallic pattern, so that a thin
and strong shell of mould is formed around the
pattern.
 The shell is removed from pattern. After that the
shell is placed into the flask with necessary back
up materials and the molten metal is poured into
the mould.
 All metals can be casted in investment process.
 Applications: Cylinders and cylinders heads for
IC engines, small crank shafts, and automobile
transmission parts, and brake arm.
Steps 1: A metal pattern is heated and
placed over a box containing sand
mixed with thermosetting resin

Step 2: Box is inverted so that sand

and resin fall onto the hot pattern,
causing a layer of the mixture to
partially cure on the surface to form a
hard shell

Step 3: Box is repositioned so

loose uncured particles drop away
Step 4: Sand shell is heated in oven for
several minutes to complete curing

Step 5: shell mold is

stripped from pattern
(5)

Step 6: Two halves of the shell mold

are assembled, supported by sand or
metal shot in a box, and pouring is
accomplished

Step 7: Finished casting

with sprue removed
(7)
 Advantages:
– Smoother surface finish than sand casting.
– Surface finish of 2.5 m can be obtained.
– Good dimensional accuracy  0.25 mm on small
to medium size parts.
– No further machining is needed.
– Capability for automation lowers the cost for
larger quantities.
 Disadvantages:
– More expensive metal pattern, especially for
small batch.
• Uses a mold of sand packed around a
polystyrene foam pattern which vaporizes when
molten metal is poured into mold
• Polystyrene foam pattern includes sprue, risers,
gating system, and internal cores (if needed)
• Mold does not have to be opened into cope and
drag sections.
• Other names: lost-foam process, lost pattern
process, evaporative-foam process, and full-mold
process
• Applications: Automobile engine,
 Step 1: Polystyrene foam pattern is
coated with refractory compound

Step 2: Foam pattern is placed in mold box,

and sand is compacted around the pattern

Step 3: Molten metal is poured into the

portion of the pattern that forms the
pouring cup and sprue. As the metal
enters the mold, the polystyrene foam is
vaporized ahead of the advancing liquid,
thus filling the mold cavity
 Advantages:
– Pattern need not be removed from the mold
– No cope /drag is needed, all features are built
into the pattern.
– Possibility for automated production.
 Disadvantages:
– A new pattern is needed for every casting.
– Economic justification of the process is highly
dependent on cost of producing patterns
• Similar to sand casting in terms of process
except the mold is made from plaster of Paris
(Gypsum).
• Plaster mold is for lower temperature alloys
while ceramic mold is for higher temperature
alloys.
 Advantages:
– Good surface finish and dimensional control.
– Capability to make thin cross sections.

 Disadvantages:
– Curing takes too long to render it unsuitable for
volume production.
• Similar to sand casting in terms of process
except the mold is made from plaster of Paris
(Gypsum).
• In mold-making, plaster and water mixture is
poured over plastic or metal pattern and allowed to
set
– Wood patterns not generally used due to
extended contact with water
• Plaster mixture readily flows around pattern,
capturing its fine details and good surface finish
• Plaster mold is for lower temperature alloys
 Advantages:
– Good surface finish and dimensional control.
– Capability to make thin cross sections.
 Disadvantages:
– Curing takes too long to render it unsuitable for
volume production.
– Mold must be baked to remove moisture
• Moisture can cause problems in casting
– Mold strength is lost if over-baked
– Plaster molds cannot stand high temperatures
• Limited to lower melting point alloys
• Similar to plaster except that mold is made of
refractory ceramic material that can withstand
higher temperatures than plaster.
• Can be used to cast steels, cast irons, and other
high temperature alloys
• Advantages (good accuracy and finish) also
similar
 Step 1: Thin pre-heated plastic sheet
sucks onto the vacuum vented pattern
surface.

Step 2: Special flask with vents and filled

with sand is placed over the pattern.

Step 3: Another plastic sheet covers the

sand and vacuum is drawn.