Module II

Metal casting processes

Instructor: Dr. Amlan Kar

Topics to be covered: Fundamentals of casting process, steps involved, Types,

Patterns and allowances, Sand mould Casting, expandable and nonexpendable
casting processes, casting defects and remedies, special types of casting
process, cast materials and defects.
No. of Lectures: 04
 Casting overview:
• Casting means pouring of molten metal into a refractory mould with a
cavity of the shape to be made, and allowing it to solidify. When
solidified, the desired metal object is taken out from the refractory
mould either by breaking the mould or taking the mould apart.
OR
• Casting is a process in which molten metal flows by gravity or other
force into a mold where it solidifies in the shape of the mold cavity.

• The solidified object is called casting.

• This process is also called foundry
Basic steps involved in casting process:

Step 1: Mold cavity preparation

Step 2: Melting process
Step 3: Pouring technique
Step 4: Solidification process
Step 5: Part removal process;
Step 6: Post processing
 1: Drag portion of pattern is placed in flask

• The diagrams shows the pattern on a flat board and a

casting box called a ‘drag’ being placed over it

2: Drag is packed with sand

• Special casting sand will soon be packed around the
pattern.
• To ensure the easy removal of pattern from the sand,
parting powder is sprinkled over and around it.
(parting powder is similar to talcum powder).
• It stops the casting sand sticking to the pattern and
pulling away with it when the pattern is finally
removed from the sand
 Step 1 contd….
3. Drag is packed with sand
• Casting sand is then shaken through a sieve.
• only fine particles fall around the pattern. This is
called facing sand and it must be fine so that detail
on the pattern shows up on the final casting.

4. Packing of sand with ram

• The drag is then packed with more casting sand. It is a
good idea to sieve all the sand being placed above the
pattern and then ram it down firmly using a ramming
tool.
• The tool has two ends,
• Cylindrical (used for general packing down of the sand)
• Pointed (Used for packing sand close up to the pattern).
6
 Step 1 contd….

5. Leveling
• When the drag is packed fully it is
leveled off (called ‘strikling off’) using
a straight steel bar.

6. Turn Over Drag

• The entire drag and its contents

are then turned over so that
the base of the pattern can be
seen.
 Step 1 contd….

7. Fixing and positioning Locating Pin

• A top box called a ‘cope’ is then placed on top of the drag
and locating pins are put in position so that the casting
boxes cannot move sideways.

8. Insert Sprue and Risers

• Sprue pins are positioned. One usually on the back of the
pattern and the other to the side. These will eventually provide
an entrance and exit for the molten aluminum when it is poured
into the sand.
The sand is packed/rammed into the cope in the same way as
the drag. Parting powder is first applied, followed by facing sand.
The sprue pins should be taller than the box and stand out from
the sand when it is levelled with a strickling bar

8
 9. Pack the cope with Sand
• Small depressions are dug into the sand at
the top of the two sprue pins. The
depressions are called the pouring basin and
feeder
10. Gates and runners cut into mold
• The top box (the cope) is then removed
and if all is well the cope with the sand
inside should lift off the drag (bottom
box) without the sand falling out. A
small ‘gate’ is cut below the position of
one of the sprue pins. This will help the
molten aluminium flow into the cavity
left by the mould. Small tools are
available or can easily be made to dig a
variety of shapes in the casting sand.
They are similar to small trowels.
 11. Removal of Pattern
• The pattern is removed using a ‘spike’. The end of the
spike can be threaded and so it can be screwed into
the softwood pattern. Before removing the pattern it
is a good idea to gently tap the spike so that it loosens
the pattern from the sand. It can then be lifted away
from the casting box (drag).

12. Closing cope and drag

• The cope (top casting box) is placed back on top of
the drag and the locating pins put in position.
• Before this is done vents can be created using a
thin piece of welding rod, pushing it through the
sand . This allows gases to escape once the
aluminium is poured
 13. Pouring of Molten Metal
• The aluminium is poured with great care.
• The molten aluminium is poured down the hole left by the first
sprue pin and then passes through the runner and ingate and
finally reaches the cavity left by the pattern. The molten metal
flows up the riser (the hole left by the second sprue pin).
• The casting should be left for sufficient time before removal from
the sand.

14. Final Casting

• When removed from the sand, the runner and riser are cut
away and the casting is ready for machining

11
Casting Terms

• Pattern
• Flask
• Cope
• Drag
• Core
• Core Box
• Core Print
• Mold Cavity

13
a) Open mould b) close mould
Casting classification:

Example:
Special casting processes
• Shell moulding
Example: • Precision investment casting
• Die casting
• Cold chamber
• Hot chamber
• Squeeze casting
• Continuous casting
• Centrifugal casting
 Casting Terms
Drag: Lower moulding flask.
Cope: Upper moulding flask.
Cheek: Intermediate moulding flask used in three piece moulding.
Pattern: Pattern is a replica of the final object to be made with some
modifications. The mould cavity is made with the help of the pattern.
Parting line: This is the dividing line between the two moulding flasks that makes up the sand mould. In split
pattern it is also the dividing line between the two halves of the pattern.
Bottom board: This is a board normally made of wood, which is used at the start
of the mould making. The pattern is first kept on the bottom board, sand is sprinkled on it and then the ramming
is done in the drag.
Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the moulding cavity
to give better surface finish to the castings.
Moulding sand: It is the freshly prepared refractory material used for making the mould cavity.
Backing sand: It is what constitutes most of the refractory material found in the mould. This is made up of used
and burnt sand.
Core: It is used for making hollow cavities in castings.
Pouring basin: A small funnel shaped cavity at the top of the mould into which the molten metal is poured.
Sprue: The passage through which the molten metal from the pouring basin reaches the mould cavity. In
many cases it controls the flow of
metal into the mould.
Runner: The passageways in the parting plane through which molten metal flow is regulated before they
reach the mould cavity.
Gate: The actual entry point through which molten metal enters mould cavity.
Chaplet: Chaplets are used to support cores inside the mould cavity to take care of its own weight and
overcome the metallo-static forces.
Chill: Chills are metallic objects which are placed in the mould to increase the cooling rate of castings to
provide uniform or desired cooling rate.
Riser: It is a reservoir of molten metal provided in the casting so that hot metal can flow back into the mould
cavity when there is a reduction in volume of metal due to solidification.
 Advantages:
• Any intricate shapes internal or external can be made.
• It is possible to cast practically any material be it ferrous or non-ferrous.
• Tools required for casting are simple and inexpensive.
• Weight reduction in design can be achieved.
• Castings have no directional properties.
• Casting of any size and weight, even upto 200 tons can be made.

Limitations:
• Dimensional accuracy and surface finish achieved by normal sand casting process
would not be adequate for final application in many cases.
• Machine moulding and foundry mechanisation is required for higher production rate.
• With some materials it is often difficult to remove defects arising out of the moisture
present in sand castings.
Applications
Typical applications of sand casting process are
• Cylinder blocks
• Liners
• Machine tool beds
• Pistons
• Piston rings
• Mill rolls
• Fly wheels
• Housings
• Water supply pipes
• Bells.