Casting Classified in to (Carbon: 2.3 % to 6.

67 %)
 Grey Cast Iron (GI) or Flake Graphite(FG) Casting --------(Flake Graphite Structure)
 Ductile Cast Iron or Nodular Cast iron or Spheroidal Cast Iron (SG) ---- (Nodular Sphere Graphite Structure)
 White Iron or Chilled Castiron
 Malleable Iron
 Compacted Graphite Iron
5 Elements of Cast Iron : (Carbon 2.0% -6.67 %)
 Carbon (C)
 Silicon (Si)
 Manganese (Mg)
 Sulphur(S)
 Phosphorous(P)
Alloys : Copper,Tin,Titanium

Properties Depends Upon

 Carbon Content
 Cooling rate of Casting
 Alloying Elements

Alloying Elements:
o Graphite producing elements Co, P, Cu, Ni, Ti, Si, C, Al
o Carbide producing elements W, Mn, Mo, S, Cr, V, Mg, Ce
o The microstructure depends on: - Carbon and Silicon content - Section size (cooling rate)

Casting Major 5 Defects:

o Gas Porosity
o Shrinkage (Open Shrinkage , Closed Shrinkage)
o Mould Material Defect
o Pouring metal Defect  (Misrun,Cold shuts,Inclsuion)
o Metallurgical Defects (Hot Tears,Hot Spots)

Cast Iron Family:

1. Grey Cast Iron -(FG Iron) (Carbon 2% - 4 %)
2. White Cast Iron
3. Mottled Iron
4. Chilled Cast Iron
5. Malleable Iron
6. Nodular Iron (SG Iron)

Steps involved in Making Casting:

I. Mould Sand Prepartion
II. Core Sand Prepartion
III. Pattern Making (Solid Pattern / Split Pattern /Match Plate Pattern /Cope & Drag Pattern)
IV. Core Making (Cold Box / Air Set Core / Shell Mould Core) (Hardener –Binder –Catylst)
V. Moulding (ARPA / HPML)
VI. Melting & Pouring (Coupola / Induction /Electric Furnance ) & (Press Pour /Manual Mono Rail)
VII. Soldification & Cooling
VIII. Shake Out
IX. Shot Blasting
X. Fettling
XI. Cleaning
Types of Green Sand Moulding
 Mechanical Tight Flask Moulding
 Automatic Flask less Moulding (Vertical DISA)
 Hand Moulding
Fast Mould Making process:
 Mechanical Sand Moulding
 Automatic high pressure sand moulding
 Horizontal Flask Sand Moulding
 Vertical Sand Flask less moulding (DISA-DISAMATIC)
 Machplate Sand Moulding

Sand Casting Termology:

I. Cope –Top Half
II. Drag – Bottom Half
III. Core – For Internal Cavities
IV. Pattern –Positive –Duplicate of Casting
V. Funnel – Sprue – Runners – Gate –Cavity –Risers or Vent
VI. Flask – It is type tool contain the Mould ( Outer body )
Pattern: It is duplicate of Product which are made in the shape of Casting Types : Solid / Split /Match Plate / Cope & drag
Core: It is used to create internal Cavities which should have similar properties of the mould (Shake out after casting
produced)

Moulding Machines:
o Jolt Machine
o Squeeze Machine
o Jolt & Squeeze Machine (ARPA : Automatic Ramming Pneumatic Application)
o Sand Slinger
ARPA is a jolt squeeze moulding machine suitable for smaller foundries requiring flexibility, good quality production of
short run castings.
Key Features:
 High frequency, low amplitude jolting with high dynamic squeeze force for uniform and rigid moulds
 Hydro-pneumatic swing in and out and precisely guided pattern draw for dame free stripping
 All parts accessible above floor level for easy maintenance

Gating System :
 Sprue : Holes Through molten metal is poured
 Runners : Networks through which molten metal flows in the mould
 Gates : Areas where molten metal enters the impression (Part)
 Risers : Reserviors of molten metal to ensure complete part filling
 Vents : Holes allowing escape of gases from the melt

Pattern – Types :
 Solid Pattern
 Split Pattern
 Match Plate Pattern
 Cope- Drag Pattern
Metal Match Plate :

Core :
 It is used to create internal Cavities (Shaken out after casting is produced)
No Bake Moulding:
 Core are made of chemical binders are used to create high strength moulds
Cold Box :
 Cores are made of foundry sand with addition of some resin for strength by means of core boxes
 Two core halves ready for baking, and the complete core made by gluing the two halves together

Choke @ Bottom

Gating Ratio :
 Sprue Area : Runner Area : Gate Area
 Non Pressurized - 1:4:4
 Pressurized : 1: 2 :1
 Total runner area and gate areas higher than the sprue area.
Types of Allowance:
Shrinkage Allowance: 0.83% to 1.3%
Machining Allowance: 2.00 to 25.00 mm
Draft & Taper Allowance: 0.5° to 2° Degree
Distortion Allowance
Rapping & Shake Allowance
Machining Stock as
 Faces : 3.5 Min/Side [ Cope: 4.0Min Drag : 3.5 Min]
 ID/OD :4.00 Min/Side [Cope 4.0 Min /Drag :3.5 Min]
As Design:
Wall Thcikness :3-4 mm Min
Linear Tolerence : 4.00mm/Metre

Typical Foundry Sand :

Foundry sand is a mixture of fresh and recycled sand, which contains 90% silica (SiO2), 3% water, and 7% clay.
Grain size and grain shape are very important as they define the surface quality of casting and the major mold parameters
such as strength and permeability:
 Bigger grain size results in a worse surface finish
 Irregular grain shapes produce stronger mold
 Larger grain size ensures better permeability

Sand Properties:
o Green Compression Strength (GCS)
o Dry Compression Strength (DCS)
o Hot Compression Strength
o Moisture ( % of water Content)
o Permeability (Porous – Gas to pass off after pouring)
o Flowability ( The Sand Should Respond Moulding)
o Refractoriness ( To Withstand High Temp)
o Thermal Stability
o Collapsibility
o Produces good casting finish
o Mold Hardness
o Deformation
o Is reusable
o Remove heat from the cooling casting
Green Sand Check Points:
 Permeability – Ability of compacted mould to pass through air (Should be “Permeable”, so gases and steam can
escape from the mould at the beginning of pouring)
 Compatibility-To know the way moulding sand will withstand repeated cycles of heating and cooling during
casting operations
 Moisture Content
 Green Compression Strength (GCS) –Sufficient Strength to Strip from pattern & Support its own wt without
deforming and withstand the pressure of molten metal. When mould to Cast
 Dry Compression Strength (DCS) -Prevent erosion by liquid metal during pouring as the mould surface dries out.
 Refractoriness –It will able to withstand high temperature
 AFS (American Fine Sand No)--- AFS GFN(Grain Fineness Number) : 57-63
 Properties like permeability, cohesiveness and green strength are dependent upon size and shape of sand grains,
as also upon the binding material and moisture content present in sand.
 Clay is a naturalbinder. Chemical binders like bentonite are sometimes added if clay content in natural sand is not
enough.
 Standard tests have been devised by foundry men to determine properties of sand. Generally fresh moulding
sand prepared in the foundry has the following composition:
 Silica         75% (approx.)
Clay          10–15%
Bentonite   2–5% (as required)
Coal dust   5–10%
Moisture    6–8%
 Sand Temp Appox 50°C

Inoculant is a substance added to a metal or alloy in small quantities, causing a significant change in its structure and
properties. The effect of such treatment is called inoculation
Inoculant is to achieve best Mechanical Properties and optimum machinability characteristics by
 Control of Graphite Structure
 Elimination or reduction of Carbide / Chill
 Reduction of Casting Sensitivity
 Promote formation of type A graphite (FG)
 Prevent formation of undercooled graphite (FG)
 Prevent formation of Rosette graphite (FG)

Different Melting Furnace :

 Induction Melting (Coreless Induction & Channel Induction) –Medium Freq –High Freq
 Rotary Furnace Melting
 Cupola Melting
Furnance Charge Capacity: 500 Kg
 Cast Iron Scrap : 400 Kg (PIG IRON)
 Mild Steel Scrap : 50 Kg (PRESS SCRAP)
 Foundry Returns : 50 Kg (RETURN SCRAP)
 Coke © : 1.5 Kg
 Silicon : 2.0 Kg
 Innoculant :0.1 %

Carbon Equivalent [CE] = C% + (Si%+P%)/3

Carbon Equivalent is Combined Effect of Carbon,Slicon & Phosphorous on physical Properties of Castiron
 Furnace Temp : 1550° C
 Tapping Temp : 1550° - 1500°C
 Pouring Temp : 1450°C
 Pouring Time : Max 7 Minutes if SG Iron

Pouring Methods:
 Mono-Rail Pouring –Where Pouring Ladle goes to the Mould Box
 Press Pouring – Where Moulding Box Come to Pouring Station
o SG Iron : Magnesium Treatment ( Mg Treatment Laddle & Conversion Laddle ) MgFeSi (Magnesium Fero Slicate)
o Magnesium Treatment Ladle to Normal Lattle

Grey Cast Iron or Flake Graphite (FG) : It is Commercial iron

 Carbon : 3 – 3.5 %
 Silicon : 1 – 2.75%
 Manganese : 0.4 -1.0%
 Phosphorous : 0.15 Max
 Sulphur :0.02 -0.15 % Other are iron
 Low Tensile Strength – High Compressive Strength – No Ductility
 It is suitable for machine tool body ,Cylinder Blocks, Fly Wheels

As per Std IS 210 -1993

 FG 150 (150 Represents – Tensile Strength 150 MPA or N/mm2) -Hardness 130 -180 BHN
 FG200 – Hardness 160 -200 BHN
 FG220 – Hardness 180 -220 BHN -Tensile Strength (N/mm2) –Specimen
 FG260 – Hardness 180 -230 BHN - Hardness (BHN)
 FG300 – Hardness 180 -230 BHN -Chemical Composition (Spectro)
 FG350 – Hardness 207 -241 BHN -Microstructure
 FG400– Hardness 207 -270 BHN -Radiography
For Grey Cast-iron relationship -Dimension Report
o Carbon Increases Tensile Strength Decrease -Casting Defects
o CE Increases Tensile Strength also Increases

Microstructure :

Graphite Distribution in Grey Castiron

Type A – Random Flake graphite in a uniform distribution
Type B - Rosette Flake graphite
Type C – Kish Graphite (Hyper Eutectic Composition)
Type D – Undercooled Graphite
Type E – Interdendritic flake graphite (Hypo eutectic Composition)
Graphite Forms: 6
Spheroidal Graphite Cast Iron (Nodular or Ductile) : It is high Strength Cast Iron
 Carbon : 3.2– 3.6 %
 Silicon : 2.2 – 2.8%
 Manganese : 0.1 -0.2%
 Phosphorous :0.005- 0.04%
 Sulphur :0.005 -0.02 %
 Maganese : 0.1-0.2%
 Copper : <0.4%
 Elements such as copper or tin may be added to increase tensile and yield strength while simultaneously
reducing ductility. Improved corrosion resistance can be achieved by replacing 15% to 30% of the iron in the
alloy with varying amounts of nickel, copper, or chromium.

 Cast iron is obtained by adding small amount of magnesium (0.1-0.8%) to the molten grey cast iron
 Addition of magnesium causes graphite to take form of small nodules or spheroids instead of angular flakes
 Shock & Impact Resistance, Good Machinality,High Fluidablity,Tensile Strength,Toughness,Wear Resistance
 Hydraulic Cylinders,Cylinder heads,Cylinder Blocks,
As per Std IS 1865 -1991
 SG900/2 – 900 Represents Tensile Strength 900MPA or N/mm2 & Min Elongation :2% -Hardenss : 280-360 BHN
 SG 800/2
 SG700/2
 SG600/3
 SG500/7
 SG450/10
 SG400/15
 SG400/18
 SG350/22
Microstructure :

Ductile Iron Microstructure Rating :

 Nodularity Rating : 50% - 60% -70% - 80% - 90% - 100%
 Pearlite Rating : Peralite% –Fearlite% –Graphite %
 Carbide Rating : 2% -4%- 9% - 18% - 21% - 27%
 Nodule Count : 300/mm2 – 200/mm2 -150/mm2 -100/mm2 – 50/mm2 – 25/mm2

Types of Riser : 1) Open Riser 2) Blind Riser

Knock Out Time : Cores & Core Making :
 Hot Box Method : A liquid thermosetting binder is added to
Shooting Time: sand and blown in to hot(230°C) core box .cures Quickly(10-
30S) & Removed
Avg Pouring Temp :  Cold Box Method : Binder+Sand Blown in to the Core box
and gas(eg.So2-Amine Gas) passed through to cure resin
Avg Melting Temp: without heat (Gases and Toxic)
Avg Pouring Temp :  Air-Set & No Bake Sands: Cold Curing binder and Shell
Process can also to make Cores
Laddle
Shoot out Time :

Factors affecting Casting Nature:

Chemical Composition
Solidification Process & Cooling rate
Microstructure

Common Defects :
o Blow Holes –Apperance as small round voids –Caused by hard ramming & Low Permeability Sands
o Misrun –Mould cavity remain unfilled
o Cold shut –In prefect fusion of molten metal in mold cavity
o Inclusion – Foreign material Present in the casting
o Shrinkage – Caused by inadequate feeding of molten metal
o Cold shuts – Improper fusion of different stream of metal
o Scar
o Blister
o Gas hole
o Pin holes
o Porosity
Common Metallurgical Defects in Ductile Iron :
 Compacted Graphite
 Exploded Graphite
 Chuncky Graphite
 Spiky Graphite

The Basic concept of Gating Design are

 Pouring Basin
 Sprue
 Runner
 Gates that feeding the casting
 Risers

Gating System Design :

 Un-Pressurized system reduces metal velocity
and turbulence (Gating Ratio – 1:4:4)
 Pressurized system usually reduce size & weight
of gating system ( Pressure at construction (gate)
causes metal to completely fill runner more
quickly (Gating Ratio -4:8:3)
 1. CRACK
2. CARBON FLOATATION (KISH)
3. SLAG & INCLUSIONS
4. SWELL
5. GAS DEFECT
6. HARD SPOTS / CHILLED AREAS
7. MIS RUNS / COLD SHUT
8. OPEN GRAIN STRUCTURE
9. SHORT POURED
10. ROUGH SURFACE
11. SHRINKAGE
12. POROSITY
13. PIN HOLES / BLOW HOLES

Considerations for Selecting a Casting Process

o Required quality of the casting surface
o Required dimensional accuracy of the casting
o Number of castings required per order
o Type of pattern and corebox equipment needed
o Cost of making the mold(s)
o How the selected process will affect the design of the casting

Green Sand Components :

 Foundry Sand
 BENTONITE = Sand Binder
 Additives
 Water
 Dead Clay

Green Sand Moulding Composition :

(Silica Sand + Dead Clay) + (Active Clay +Combustiblies)+Water
REFRACTORY +ABSORBENTS+CATALYST

The Green Sand Formula depends mainly on:

-the type of sand plant (mixer, cooling system, etc..)
-the type of moulding process
-the type of shake-out process
-the materials used (new sand, bentonite, additives, etc…)
-the castings produced (sand/metal ratio, type of metal, etc..)

Gas Defects: Blow Holes – Porosity – Pin holes-Inclusion

Blowholes:
Outer Surface thicker section shows rough shaped Holes
Causes:
 High Moisture Content
 Low Permeability of Moulding Sand
 Insufficient Venting in Moulds
Solution:
 Improve Permeability using Vent holes
 Reduce Moisture Content
 Avoid Excess ramming – Mould hardness
Porosity:
Cavities appears in machining surface – Gas can be trapped in to air, hydrogen
Causes:
 Wrong Pouring Composition of Metal
 Improper runner & Feeding
 Used of Impermeable Mould
 Pouring too Slow
 Insufficient Metal Fluidity (eg : CE is Low)
 Slag on metal Surface
 High gas pressure in the mould arising from moulding
Solution:
 Reduce Sulphur & Phosphorous content in charge
 Improve venting of mould
 Reduce gas pressure in the mould by adjust to mold material properly
 Modify metal composition

Shrinkage
Rough cavities at heavy section or a joints and which there is change of Section
Causes :
 Incorrect gating & Feeding
Solution :
 Use Separate risers to feed heavy Section

Cold Shut
Dividing zone where streams of melt fails to merge in molten condition
Causes :
 Low Pouring temp / Melting Temp
 Lack of fluidity of alloy
 Tool much gas forming material in facing sand
 Poor gating system
Solution :
 Modify system of moulding
 Ensure correct pouring temp for alloy
 Modify gating system

Misrun :
Cavity due to Incomplete filling mainly found in thin section
Metal is unable to fill the mould cavity complete & thus leaving unfilm portion is called Misran
Causes :
 Low Pouring Temp
 Low Fluidity
 Inadequate Venting
 Faulty pouring temp
 Faulty gating
Solution :
 Reduce heat loss in ladle by using flux covering
 Modify gating system
 Modify design

Mismatch
Two or more section of cast product fail alignment
Causes :
 Improper position of cope & Drag
Solution :
 Take Care align cope & Drag
 Check pattern dowel pin
 Check Tight fit the box pin
Rough Surface :
Causes :
 Open Moulding sand
 Low coal dust content
 Uneven ramming the metal Penetration on the mould
 AFS
Solution:
 Ram Sand More Evently
 Add Coal Dust
 Use fine Sand

Crack
Hairline Crack
Causes :
 High dry strength of sand
 Too hard cores
Solution :
 Reduce oil content
 Ram evenly

Surface Defects Internal Defects Visible Defects

 Blow Holes  Blow Holes  Wash
 Scar  Gas Holes  Swell
 Blister  Porosity  Misrun
 Drop  Pinholes  Cold Shut
 Scap  Inclusion  Shrinkage
 Penetration  Dross  Shift
 Buckle  Hot Tear
 Rat Tail
How Gating Design and Basics of Gating?
What is the chilling Effect in Casting?
What is Radiography? Uses?
What is Marking of Casting?
What is Cold Box ? Un bake –Cold Box done in Moulding machine with help Amine Gas
Advantages of ARPA, DISCA, HPML
Advantages of Vertical & Horizontal Poring ?
What are Copula Furnace vs Induction Furnace?
Why Pig Iron not used in Induction Furnace?
Mould Hardness ? Min 75 ARPA Min 80 (H) & Min 85 (V) -HPML
Sand AFS No ?
What are the Sand check Points? AFS No – Permeablity-GCS-GCShear Strength-Mould Hardness- Moisture-Volatile
-Ignition
What are the Mould Check Points? –Mould Hardness – Match plate alignement
What is the Pouring Temp ?
What is time taken between Induction Furnace to Poruing time?
What is Ladder? It is used to tap the molten metal from furnace to Mould
What is shooting time?
What is meant by Knock out? Explain? After Solidification Removed the Casting from the Flask
What is Core Coating? Baking Temp Time?
Difference of Microstructure of SG vs FG
Tell me the II III
Properties of SG ,FG
Casting – Average Surface Roughness??
Shot blasting vs sand blasting?
Shot blasting spec and control
Parameters affecting Surface Finish
Parameters affecting the microstructure?
Parameters affecting the Crack,?
Parameters affecting core hardness Low?
Which material suitable for further heat treatment?
Casting material properties related to Machinability
Carbon equivalent vs microstructure vs tensile strength?
Perlite-Ferlite-Maternsite-austainte
What are the factors affecting to Crack ?
What are the Factors affecting the Microstructure Type D & Type E ? Type D-UnderCooled Type E-Interdenite
What is the Inoculant? What is the Uses ?
What is the Tapping Temp?
What is Chapplet in Casting?

Sulfur, when present, forms iron sulfide, which prevents the formation of graphite and increases hardness. 
The problem with sulfur is that it makes molten cast iron viscous,  which causes short run defects.

To counter the effects of sulfur, manganese is added because the two form into manganese sulfide instead
of iron sulfide. The manganese sulfide is lighter than the melt so it tends to float out of the melt and into the
slag.  The amount of manganese required to neutralize sulfur is 1.7 × sulfur  content + 0.3%. If more than
this amount of manganese is added, then manganese carbide forms, which increases hardness and
chilling, except in grey iron, where up to 1% of manganese increases strength and density.[3]

Nickel is one of the most common alloying elements because it refines the pearlite and graphite structure,
improves toughness, and evens out hardness differences between section thicknesses.

Chromium is added in small amounts to the ladle to reduce free graphite, produce chill, and because it is a
powerful carbide stabilizer; nickel is often added in conjunction.

A small amount of tin can be added as a substitute for 0.5% chromium.

Copper is added in the ladle or in the furnace, on the order of 0.5–2.5%, to decrease chill, refine graphite,
and increase fluidity.

Molybdenum is added on the order of 0.3–1% to increase chill and refine the  graphite and pearlite
structure; it is often added in conjunction with  nickel, copper, and chromium to form high strength irons.

Titanium is added as a degasser and deoxidizer, but it also increases fluidity.

0.15–0.5% vanadium is added to cast iron to stabilize cementite, increase hardness, and increase
resistance to wear and heat.

0.1–0.3% zirconium helps to form graphite, deoxidize, and increase fluidity.[3]

In malleable iron melts, bismuth is added, on the scale of 0.002–0.01%, to increase how much silicon can
be added.

In white iron, boron is added to aid in the production of malleable iron; it also reduces the coarsening effect
of bismuth.[3]

Tell me the Casting Parts

Tell me the Casting Source
Tell me the Machining Source
Elements Effects
Range % Grey Iron Range % Ductile (SG) Iron Range % Malleable irons

Carbon 2.8 - 3.7 Reduces tensile strength 3.4 - 3.7
(C) and hardness. High
levels promote coarse
graphite and open-grain
on machining. Increases
thermal conductivity.
Promotes maximum
soundness with carbon
equivalent values at 4.3.
Increases fluidity.
Promotes graphite nodule 2.4 - 2.6 Blackheart : High levels
flotation in hypereutectic induce primary graphite
irons. Levels below 3.5 % formation (mottle). Low
adversely affect levels promote hot-tears
soundness. Increases and shrinkage porosity.
fluidity. 3.0 - 3.3 Whiteheart : high levels
induce primary-graphite
formation (mottle).

Silicon 1.4-2.8 Promotes formation of
(Si) ferrite. Reduces strength
and hardness. Reduces
"chilling" tendency.
Levels above 2.8 %
embrittle and harden
iron.
Manganese 0.4 - 0.9 Combines with and
(Mn) neutralises sulphur.
When present at levels in
accordance with Mn % =
1.7 x S % + 0.3 results in
lowest strength and
hardness. Mild pearlite
promoter. High levels
increase risk of dross
and manganese sulphide
blow-holes.
Reduces chilling 1.2 - 1.6
tendency. Promotes
formation of ferrite.
Increases hardness and 0.6 - 0.8
tensile strength of ferritic
grades. Increases ductile-
brittle transition
temperature. Accelerates
pearlite and carbide
breakdown during heat
treatment.
Up to 0.5 Mild pearlite promoter.
Should be below 0.2 % in
as-cast ferritic grades.
Segregates to grain
boundaries in slow-
cooled sections and
promotes carbides.
Increases transition
temperature.
Blackheart : Accelerates
carbide breakdown and
ferritization.
Whiteheart : As for
Blackheart material.
The effects of sulphur and
manganese cannot be considered
separately.
Blackheart : To produce a ferritic
matrix the sulphur must be
balanced by manganese. Mn %
must be greater than S % x 1.7. If
manganese low, annealability is
retarded, resulting in retained
pearlite and possibly carbides.
High hardness and low elongation.

Whiteheart : Excess manganese

Sulphur 0.02 - Promotes formation of < 0.015 Excessive levels in
(S) 0.16 white iron unless
balanced by manganese.
Effects on hardness and
strength see Manganese.
High sulphur promotes
dross and tendency for
manganese sulphide
blow-holes. Levels less
base-iron increase
tendency for dross
defects. Levels above
0.015 % promote
formation of poor
graphite nodules and
quasi-flake graphite.
promotes ferritic cores, loose
graphite aggregates, low tensile
strength and high ductility. Excess
sulphur promotes pearlitic cores,
spherulitic graphite, high tensile
strength and low ductility.
The effects of sulphur and
manganese cannot be considered
separately.
Blackheart : To produce a ferritic
matrix the sulphur must be
balanced by manganese. Mn %
must be greater than S % x 1.7. If
manganese low, annealability is
 than 0.05 % reduce retarded, resulting in retained
response to inoculation pearlite and possibly carbides.
treatment. High hardness and low elongation.

Whiteheart : Excess manganese

promotes ferritic cores, loose
graphite aggregates, low tensile
strength and high ductility. Excess
sulphur promotes pearlitic cores,
spherulitic graphite, high tensile
strength and low ductility.

Phosphorus 0.02 - 1.2 Increases hardness and < 0.05 Above 0.05 % can
(P) brittleness. Increases
tendency for internal
unsoundness defects.
At low levels (0.04 %),
increases metal-
penetration and finning.
< 0.05 Increases ductile-brittle
produce internal transition temperature.
unsoundness defects. Promotes galvanizing
Embrittles the iron - raises and temper
ductile-brittle transition embrittlement.
temperature. Promotes
galvanizing and temper-
embrittlement. Segregates
to grain boundaries and
produces
carbide/phosphide
complexes.

Foundry Visit :
1. Chougle Industries – ARPA – Manual Pouring
2. Sound Casting –ARPA –Automatic Moulding – Press Pouring & Mono Rail Pouring
3. Ghaghe Patel Casting – Automatic Moulding –Press Pouring
4. Ashok iron Works – ARPA – Automatic Moulding –Press Pouring & Mono Rail Pouring
5. C Gopal Naicker – ARPA –Manual Pouring
6. Jothi Mirco cast – DISA – Flask Less – Mono Rail Pouring
7. Lotus Engg –DKD Foundries – ARPA – Manual Pouring
8. Sanmar Foundries –DISA-Flaskless –Press Pouring
9. AKP Ferocast – ARPA – Manual Pouring

Kungal Warner –Automatic HPML Moulding – German Make

Development time of Casting:
Sand Casting : 2 - 10 Weeks
Investment Casting : 5 - 16 Weeks
Die Casting : 12 -20 Weeks
**Development time is also depends on the size and complexity
Production rate is depending on the Cooling Time

Small & Medium Casting Wt: Less than 25 Kg – Min Lead time 45-60 Days
Heavy Casting Wt: More than 50 Kg –Min Lead Time 90 Days

Casting Basic Developemnt Process:

I. R&D Drg / Model Release for Development
II. Based on the Product Selection of Supplier – Box Size Availability – HPML –etc
III. Supplier will provide the Feasibility Proposal Model of Part based on the Sand Plant
IV. Discuss with R&D And Conculate the Model
V. Make a Pattern / Mould Design & Simulation
VI. Manufacturing of Mould & Patten
VII. Inspection of Mould & Pattern
VIII. Trail
IX. Verification
Compare Grey CastIron vs Ductile CastIron (SG)

Grey CastIron Ductile CastIron

Contain Small & Interconnected Graphite in a form of Graphite in a form of Spheroidal Shape
Flake Type Shape Contain Pearlite and Sphere like Graphite

Addition of Magnesium to induce nodularization of

No of addition of Magnesium (Mg) & Ce
graphite
Tensile Strength 150 -400 Mpa Tensile Strength 350-800 Mpa
Low Tensile Strength High Tensile Strength

No Elongation Elongation 3% - 20%

No Ductility High Ductility

High Compressive Strength High Impact Strength 

Good Damping / Vibration

Good thermal Conductivity  

Good resistance to Thermal Fatigue  

Dry & Normal Wear Property Excellent Wear Resistance  & High Fluidablity

Machine Casing ,Cover , Machine tool body ,Cylinder

Hydraulic Cylinders,Cylinder heads,Cylinder
Blocks, Fly Wheels
Blocks,Brake Pedals,brake disc,Calipers

..