Kalpakjian Casting

Chapter 10
Fundamentals of Metal Casting
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Solidification of Pure Metals
Figure 10.1 (a) Temperature as a function of time for the solidification of pure metals. Note
that the freezing takes place at a constant temperature. (b) Density as a function of time
Cast Structures of Solidified Metals
Figure 10.3 Development of a

preferred texture at a cool mold
wall. Note that only favorably
oriented grains grow away from
Figure 10.2 Schematic illustration of three the surface of the mold
cast structures of metals solidified in a square
mold: (a) pure metals; (b) solid-solution
alloys; and (c) structure obtained by using
nucleating agents. Source: After G. W. Form,
J. F. Wallace, J. L. Walker, and A. Cibula
Alloy Solidification
Figure 10.4 Schematic illustration of alloy solidification and temperature distribution

in the solidifying metal. Note the formation of dendrites in the mushy zone.
Solidification of Iron and Carbon Steels
Figure 10.5 (a) Solidification patterns for gray cast iron in a 180-mm (7-in.) square casting.
Note that after 11 minutes of cooling, dendrites reach each other, but the casting is still mushy
throughout. It takes about two hours for this casting to solidify completely. (b) Solidification of
carbon steels in sand and chill (metal) molds. Note the difference in solidification patterns as
the carbon content increases. Source: After H. F. Bishop and W. S. Pellini
Basic Types of Cast Structures
Figure 10.6 Schematic illustration of three basic types of cast structures: (a) columnar
dendritic; (b) equizxed dendritic; and (c) equiaxed nondendritic. Source: Courtesy of D. Apelian
Cast Structures
Figure 10.7 Schematic illustration of cast structures in (a) plane front, single
phase, and (b) plane front, two phase. Source: Courtesy of D. Apelian
Fluid Flow and Solidification Time
p v2
Bernoulli’s theorem h    constant
g 2g
Mass continuity Q  A1v1  A2v2
A1 h
Sprue design  2
A2 h1
vD
Reynolds number Re 

 Volume n
Chvorinov’s Rule Solidification time = C 
Surface Area 
Casting Design and Fluidity Test
Figure 10.9 A test method for

Figure 10.8 Schematic illustration of a typical fluidity using a spiral mold. The
riser-gated casting. Risers serve as reservoirs, fluidity index is the length of the
supplying molten metal to the casting as it solidified metal in the spiral
shrinks during solidification. passage. The greater the length
of the solidified metal, the greater
is its fluidity.
Temperature Distribution during Metal Solidification
Figure 10.10 Temperature

distribution at the interface
of the mold wall and the
liquid metal during the
solidification of metals in
casting
Solidified Skin on a Steel Casting
Figure 10.11 Solidified skin on a steel casting. The remaining molten metal is poured out
at the times indicated in the figure. Hollow ornamental and decorative objects are made by
a process called slush casting, which is based on this principle. Source: After H. F. Taylor,
J. Wulff, and M. C. Flemings
Solidification Contraction or Expansion
Hot Tears in Castings
Figure 10.12 Examples of hot tears in castings. These defects occur because the
casting cannot shrink freely during cooling, owing to constraints in various portions
of the molds and cores. Exothermic (heat-producing) compounds may be used (as
exothermic padding) to control cooling at critical sections to avoid hot tearing
Common Casting Defects
Figure 10.13 Examples of common defects in castings. These defects can be

minimized or eliminated by proper design and preparation of molds and control of
pouring procedures. Source: After J. Datsko.
Types of Internal and External Chills used in Casting
Figure 10.14 Various types of (a) internal and (b) external chills (dark areas at
corners) used in castings to eliminate porosity caused by shrinkage. Chills are
placed in regions where there is a larger volume of metal, as shown in (c).
Solubility of Hydrogen in Aluminum
Figure 10.15 Solubility of

hydrogen in aluminum. Note the
sharp decrease in solubility as
the molten metal begins to
solidify.
Casting of an Aluminum Piston
Figure 10.16 Aluminum piston for an Figure 10.17 Simulation of mold filling
internal combustion engine: (a) as- and solidification. (a) 3.7 seconds after
cast and (b) after machining. start of pour. Note that the mushy zone
has been established before the mold is
filled completely. (b) Using a vent in the
mold for removal of entrapped air, 5
seconds after pour.
Chapter 11
Metal-Casting Processes
Summary of Casting Processes
Typical Cast Parts
(c)
(a)
(b) (d)
Figure 11.1 (a) Typical gray-iron castings used in automobiles, including the transmission
valve body (left) and the hub rotor with disk-brake cylinder (front). Source: Courtesy of
Central Foundry Division of General Motors Corporation. (b) A cast transmission housing.
(c) The Polaroid PDC-2000 digital camera with a AZ191D die-cast high-purity magnesium
case. (d) A two-piece Polaroid camera case made by the hot-chamber die-casting process.
Source: Courtesy of Polaroid Corporation and Chicago White Metal Casting, Inc.
Characteristics of Casting
Production Steps in Sand-Casting
Figure 11.2 Outline of production steps in a typical sand-casting operation.
Sand Mold
Figure 11.3 Schematic illustration of a sand mold, showing various features.
Pattern Plate
Figure 11.4 A typical metal match-plate pattern used in sand casting.
Design for Ease of Removal from Mold
Figure 11.5 Taper on patterns for ease of removal from the sand mold
Sand Cores
Figure 11.6 Examples of sand cores showing core prints and chaplets to support cores.
Vertical Flaskless Molding
(c)
Figure 11.7 Vertical flaskless molding. (a) Sand is squeezed between two
halves of the pattern. (b) Assembled molds pass along an assembly line
for pouring. (c) A photograph of a vertical flaskless molding line. Source:
Courtesy of American Foundry Society.
Sequence of
Operations for
Sand-Casting
Figure 11.8 Schematic illustration of the sequence of operations for sand casting. (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 on next slide.
Sequence of
Operations for
Sand-Casting,
Con’t.
(g) The flask is rammed with sand and rthe plate and inserts are removed. (h) 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 securing the assembly with pins.
The flasks the are subjected to pressure to counteract 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). Source: Courtesy of Steel Founder’s Society of America
Shell-Molding Process
Figure 11.9 The shell-molding process, also called dump-box technique.

Sequence of Operations in Making a Ceramic Mold
Figure 11.10 Sequence of operations in making a

ceramic mold. Source: Metals Handbook, Vol. 5, 8th ed.
Expandable-Pattern Casting Process
Figure 11.11 Schematic illustration of the expandable-pattern casting process, also

known as lost-foam or evaporative casting.
Evaporative Pattern Casting of an Engine Block
(a) (b)
Figure 11.12 (a) Metal is poured into mold for lost-foam casting of a 60-hp. 3-cylinder
marine engine; (b) finished engine block. Source: Courtesy of Mercury Marine.
Investment Casting Process
Figure 11.13 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: Courtesy of Steel Founder’s Society of America.
Integrally Cast Rotor for a Gas Turbine
Figure 11.14 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: Courtesy of
Howmet Corporation.
Comparison of Investment-Cast and
Conventionally Cast Rotors
Figure 11.15 Cross-section and microstructure of two rotors: (top)

investment-cast; (bottom) conventionally cast. Source: Advanced
Materials and Processes, October 1990, P. 25. ASM International.
Vacuum-Casting
Figure 11.16 Schematic illustration of the vacuum-castin process. Note that

the mold has a bottom gate. (a) Before and (b) after immersion of the mold
into the molten metal. Source: After R. Blackburn.
Hot-Chamber Die-Casting
Figure 11.17 Schematic illustration of the hot-chamber die-casting process.
Cold-Chamber Die-Casting
Figure 11.18 Schematic illustration of the cold-chamber die-casting process.

These machines are large compared to the size of the casting, because high
forces are required to keep the two halves of the dies closed under pressure.
Properties and Applications of Die-Casting Alloys
Types of Cavities in Die-Casting Die
Figure 11.19 Various types of cavities in a die-casting die.

Source: Courtesy of American Die Casting Institute.
Centrifugal-Casting Process
Figure 11.20 (a) Schematic illustration of the centrifugal-casting process. Pipes,

cylinder liners, and similarly shaped parts can be cast with this process. (b) Side
view of the machine.
Semicentrifugal Casting and Casting by Centrifuging
Figure 11.21 (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.
Squeeze-Casting
Figure 11.22 Sequence of operations in the squeeze-casting process.

This process combines the advantages of casting and forging.
Methods of Casting Turbine Blades
(c)
Figure 11.23 Methods of casting turbine blades: (a) directional solidification; (b) method to
produce a single-crystal blade; and (c) a single-crystal blade with the constriction portion still
attached. Source: (a) and (b) After B. H. Kear, (c) Courtesy of ASM International.
Crystal Growing
Figure 11.24 Two methods of crystal growing: (a)

crystal pulling (Czochralski process) and (b) the
floating-zone method. Crystal growing is important
especially in the semiconductor industry. (c) A single-
crystal ingot produced by the Czochralski process.
(c)
Source: Courtesy of Intel Corp.
Melt-Spinning
(b)
Figure 11.25 (a) Schematic illustration of melt-spinning to produce thin strips of

amorphous metal. (b) Photograph of nickel-alloy production through melt-spinning.
Source: Siemens AG
Types of Melting Furnaces
Figure 11.26 Two types of melting furnaces used in foundries:

(a) crucible, and (b) cupola.
Chapter 12
Metal Casting, Design, Materials, and
Economics
General Design Rules for Casting
• Design the part so that the shape is cast easily.

• Select a casting process and material suitable for the part, size, mechanical
properties, etc.
• Locate the parting line of the mold in the part.
• Locate and design the gates to allow uniform feeding of the mold cavity with molten
metal.
• Select an appropriate runner geometry for the system.
• Locate mold features such as sprue, screens and risers, as appropriate.
• Make sure proper controls and good practices are in place.
Locating and Designing Gates
• Multiple gates often are preferable and are necessary for large parts.
• Gates should feed into thick sections of castings.
• A fillet should be used where a gate meets a casting; this feature produces less
turbulence than abrupt junctions.
• The gate closest to the sprue should be placed sufficiently far away so that the gate
can be easily removed.
• The minimum gate length should be three to five times the gate diameter, depending
on the metal being cast.
• Curved gates should be avoided, but when necessary, a straight section in the gate
should be located immediately adjacent to the casting.
Riser Design
• The riser must not solidify before the casting.

• The riser volume must be large enough to provide a sufficient amount of liquid metal
to compensate for shrinkage in the cavity.
• Junctions between casting and feeder should not develop a hot spot where shrinkage
porosity can occur.
• Risers must be placed so that the liquid metal can be delivered to locations where it is
most needed.
• There must be sufficient pressure to drive the liquid metal into locations in the mold
where it is most needed.
• The pressure head from the riser should suppress cavity formation and encourage
complete cavity filling.
Design Rules for Casting
Figure 12.1 Suggested design modifications to avoid defects in castings

Elimination of Hot Spots
Figure 12.2 Examples of designs showing the importance of maintaining

uniform cross-sections in castings to avoid hot spots and shrinkage cavities.
Shrinkage Allowance for Casting in Sand Molds
Examples of Good and Poor Designs
Figure 12.3 Examples of undesirable (poor) and desirable (good) casting designs.
Source: Courtesy of American Die Casting Institute.
Mechanical Properties
for Cast Alloys
Figure 12.4 Mechanical properties for

various groups of cast alloys. Note that
even within the same group, the
properties vary over a wide range,
particularly for cast steels. Source:
Courtesy of Steel Founders’ Society of
America.
Casting Applications and Characteristics
Properties and Applications of Cast Irons
Mechanical Properties of Gray Cast Irons
Properties and Applications of Nonferrous Cast Alloys
Cost Characteristics of Casting
Automated Shell
Production
Figure 12.5 A robot generates a

ceramic shell on wax patterns
(trees) for investment casting. The
robot is programmed to dip the
trees and then place them in an
automated drying system. With
many layers, a thick ceramic shell
suitable for investment casting is
formed. Source: Courtesy of
Wisconsin Precision Casting
Corporation

Kalpakjian Casting

Uploaded by

Copyright:

Available Formats

You might also like

Kalpakjian Casting

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Kalpakjian Casting

Uploaded by

Copyright:

Available Formats

Chapter 10

Fundamentals of Metal Casting

Figure 10.3 Development of a

Figure 10.4 Schematic illustration of alloy solidification and temperature distribution

Mass continuity Q  A1v1  A2v2

Figure 10.9 A test method for

Figure 10.10 Temperature

Figure 10.13 Examples of common defects in castings. These defects can be

Figure 10.15 Solubility of

Figure 11.2 Outline of production steps in a typical sand-casting operation.

Figure 11.3 Schematic illustration of a sand mold, showing various features.

Figure 11.4 A typical metal match-plate pattern used in sand casting.

Figure 11.9 The shell-molding process, also called dump-box technique.

Figure 11.10 Sequence of operations in making a

Figure 11.11 Schematic illustration of the expandable-pattern casting process, also

Figure 11.13 Schematic illustration of investment casting (lost-wax) process.

Figure 11.15 Cross-section and microstructure of two rotors: (top)

Figure 11.16 Schematic illustration of the vacuum-castin process. Note that

Figure 11.17 Schematic illustration of the hot-chamber die-casting process.

Figure 11.18 Schematic illustration of the cold-chamber die-casting process.

Figure 11.19 Various types of cavities in a die-casting die.

Figure 11.20 (a) Schematic illustration of the centrifugal-casting process. Pipes,

Figure 11.22 Sequence of operations in the squeeze-casting process.

Figure 11.24 Two methods of crystal growing: (a)

Figure 11.25 (a) Schematic illustration of melt-spinning to produce thin strips of

Figure 11.26 Two types of melting furnaces used in foundries:

• Design the part so that the shape is cast easily.

• The riser must not solidify before the casting.

Figure 12.1 Suggested design modifications to avoid defects in castings

Figure 12.2 Examples of designs showing the importance of maintaining

Figure 12.4 Mechanical properties for

Figure 12.5 A robot generates a

You might also like