University of Technology

Production Engineering and Metallurgy Department

CAD/CAM
1st class
Dr. Baraa Mohsen

Manufacturing Processes
2021-2022

Lecture 2
Ferrous and Nonferrous casting
processes
Contents
1. Introduction.
2. Metals for Casting.
3. Ferrous Casting Alloys.
3-1 Cast Iron.
3-2 Stainless Steel.
3-3 Steel.
4- Process description of mini mill.
5- General composition, properties and applications for ferrous
casting alloys.
6-Non- Ferrous Casting Alloys.
6-1 Aluminum alloys.
6-2 Copper Alloys.
6-3 Zinc alloys.
7- General composition, properties and applications for non-ferrous
casting alloys.

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1-Introduction.
When casting charge ready melting after clearing process
and adding to its demanding casting elements, then it is
pouring in the ladle called (Pouring Ladle) which is a big steel
ladle normally lined with thermal stones and furnished with
a rod in each side for handling facilitate. To prevent the slug
which collected at the melting steel surface to pass through
the casting mould so the melting steel pouring from the ladle
bottom.

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Fig.1: Two common types of ladles: (a) crane ladle and (b) two-man ladle.

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For this reason the external steel layer will contain a hole coated
by thermal material, and the seal will control the melting steel
through it, the controlled sealed connected with a rod controls the
up and down moving, the sealed its self-closed by protected cover
manufactured thermal material which controls the pouring rate,
the ladle must be heated before the charging of melting steel by
ignition and the oxygen can be eliminated from the melting steel
adding one the following materials like Ferromanganese,
Ferrosilicon or Aluminum. The ladle will be left for enough period
time until the slug and impurities appear on the surface before
pouring the metal into casting mold.
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2- Metals for Casting.
Most commercial castings are made of alloys rather than pure
metals– Alloys are generally easier to cast, and properties of
product are better. Casting alloys can be classified as:
* Ferrous
* Nonferrous
3-Ferrous Casting Alloys, such as:
3-1 Cast Iron.
• Most important of all casting alloys.-
• Tonnage of cast iron castings is several times that of all other
metals combined.
• Several types: (1) gray cast iron, (2) nodular iron, (3) white cast
iron, (4) malleable iron, and (5) alloy cast irons.
• Typical pouring temperatures 1400°C (2500°F), depending on
composition.

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3-2 Stainless steel.
The corrosion resistant, cast, stainless steel grades are grouped
into families based on their microstructure (martensitic,
austenitic, or duplex). General characteristics of each stainless
steel family and specific information about each of the widely
used grades are provided in the following sections. Stainless
steel castings are classified as “corrosion resistant" if they are
used in aqueous environments and vapors below 1200°F (650°C).
For a stainless steel casting to perform well in a corrosive
environment, the carbon content and quantity of precipitated
carbides in the microstructure must be low. The carbon content
in corrosion resistant grades is usually below 0.20% and
sometimes below 0.03%. Increasing the chromium content
enhances corrosion resistance and nickel increases resistance to
strong acids, particularly reducing acids.
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3-3 Steel.
• The mechanical properties of steel make it an attractive
engineering material.

• The capability to create complex geometries makes casting an

attractive shaping process.

• Difficulties faced by the foundry working with steel.

• Pouring temperature of steel is higher than for most other casting

metals 1650°C (3000°F).

• At these temperatures, steel readily oxidizes, so molten metal

must be isolated from air.

• Molten steel has relatively poor fluidity.

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4-Process Description of mini mill.
In a mini-mill, scrap metal is melted and refined in an electric arc furnace
(EAF) to make steel products. Generally, molten steel is produced in an
EAF and then tapped from the EAF to a ladle. The molten steel is then
usually further refined with the addition of alloys. Semi-finished product
is then produced using continuous casting or ingot casting. Multiple
finishing processes may then be used to produce finished steel products.
A general flow diagram for a mini-mill is presented in Figure 2.
The amount, type, age, and operation of equipment used in mini-mills
varies widely. Some facilities operate one or more small EAFs and have
relatively low production volume of finished goods. Other facilities
operate multiple EAFs, Argon Oxygen Decarburization (AOD) and other
refining processes, casters and product finishing lines. Some facilities
produce steel in a narrow composition range; other facilities produce a
wide variety of types and metallurgies of steel products. Some facilities
can recycle only certain types of ferrous scrap, other facilities produce
products that can be made utilizing scrap metal from a variety of sources.
All of these factors affect the quantity and characteristics of emissions.
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Fig. 2 General Flow Diagram of a Steel Mini-mill
5- General composition, properties and applications for ferrous
metals and alloys see table1

Table-1 General composition, properties and applications for

Ferrous Metals and alloys.
Material Composition Properties Applications
name
Low Up to 0.30% Good 0.1% - 0.2% carbon: Chains, stampings,
Carbon Carbon formability, rivets, nails, wire, pipe, 0.2% - 0.3% carbon:
Steels good weld- Machine and structural parts
ability, low
cost
Medium 0.30% to A good 0.3% - 0.4% carbon: Lead screws, gears,
Carbon 0.80% balance of spindles, shafts, and machine parts. 0.4% -
Steels Carbon properties, 0.5% carbon: Crankshafts, gears, axles, tool
fair shanks, and heat-treated machine parts.
formability 0.6% - 0.8% carbon: "Low carbon tool steel"
and is used where shock strength is wanted.
Drop hammer dies, screwdrivers. 0.7% - 0.8%
carbon: Tough and hard steel, band saws,
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hammers, and cable wire.
High 0.80% to Low 0.8% - 0.9% carbon: Punches for metal, rock
Carbon ~2.0% toughness, drills, shear blades, rivet sets, and many hand
Steels Carbon formability , tools. 0.9% - 1.0% carbon: Used for hardness
and weld- and high tensile strength, springs, cutting
ability, high tools. 1.0% - 1.2% carbon: Drills, taps, milling
hardness and cutters, knives, cold cutting dies. 1.2% - 1.3%
wear carbon: Files, reamers, knives, tools for cutting
resistance, wood and brass. 1.3% - 1.4% carbon: Used
fair where a keen cutting edge is necessary
formability (razors, saws, etc.) and where wear resistance
is important.

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Stainless Stainless steel is a Good corrosion
Steel family of corrosion resistance,
resistant steels. They appearance, and
contain at least mechanical
10.5% properties.
chromium, The
Chromium in the
alloy forms a self-
healing protective
clear oxide layer. This
oxide layer gives
stainless steels their
corrosion resistance.
Austenitic Steels: Good mechanical Kitchen sinks, architectural
Contains chromium and corrosion applications such as roofing,
and nickel. The resisting doors and windows; Food
typical chromium properties, high processing equipment; Heat
content is in the hardness and exchangers; Ovens; Chemical
range of 16% to 26%; yield strength as tanks
nickel content is well as excellent
commonly less than ductility and are
35%. usually non-
magnetic 13
Stainless Ferritic Steels: Good ductility, Catalytic converters,
Steel Magnetic with a high weldability, and radiator caps, fuel lines,
chromium and low formability; cooking utensils,
nickel content reasonable thermal architectural and domestic
usually alloyed with conductivity, and appliance trim applications.
other elements such corrosion resistance
as aluminum or with a good bright
titanium. surface appearance
Martensitic teels: Good combination of Scissors, surgical
Typically contains corrosion resistance instruments, wear plates,
11.0% to 17.0% and excellent garbage disposal shredder
chromium, no nickel, mechanical lugs, industrial knives,
and 0.10% to 0.65% properties, produced vanes for steam turbines,
carbon levels. The by heat treatment, shafts, and springs.
high carbon enables to develop maximum
the material to be hardness, strength,
hardened by heating and resistance to
to a high abrasion and
temperature, erosion.
followed by rapid
cooling (quenching).

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6-Non-ferrous Casting Alloys:
6-1-Aluminum alloys.
• Generally considered to be very castable.
• Pouring temperatures low – melting temperature of aluminum
Tm = 660°C (1220°F).
Properties: Light weight, Range of strength properties by heat
treatment, Ease of machining.
6-2-Copper Alloys.
• Includes bronze, brass, and aluminum bronze.
Properties:
• Corrosion resistance.
• Attractive appearance.
• Good bearing qualities.
Limitation: high cost of copper.
Applications: pipe fittings, marine propeller blades, pump
components, ornamental jewelry.
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6-3-Zinc Alloys.
• Highly castable, commonly used in die casting.
• Low melting point – melting point of zinc Tm = 419°C (786°F).
• Fluidity for ease of casting.

Properties:
• Low creep strength, so castings cannot be subjected to
prolonged high stresses.

7-General composition, properties and applications for Ferrous

Metals and alloys, see table-2

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Table-2 General composition, properties and applications for non-Ferrous Metals and
alloys.
Material Composition Properties Applications
name
Aluminum Pure metal / Easily Low density, good electrical Window frames,
/ alloyed with small conductivity (approx. 60% of aircraft parts,
Aluminum amounts of copper, copper), nonmagnetic, automotive parts,
alloys manganese, silicone, noncombustible, ductile, kitchenware.
magnesium, and malleable, corrosion
other elements. resistance.
Brass Alloy of copper and Reasonable hardness; casts, Parts for electrical
zinc, 65% to 35% is forms, and machines well; fittings, valves,
the common ratio. good electrical conductivity forgings, ornaments,
and acoustic properties. musical instruments.
Copper Pure metal Excellent ductility, thermal Electrical wiring,
and electrical conductivity. tubing, kettles,
bowls, pipes, printed
circuit boards.
Lead Pure metal Heaviest common metal, Pipes, batteries,
ductile, and malleable, good roofing, protection
corrosion resistance. against X-Rays. 17
Magnesium Pure metal / Used as an Lightest metallic Automobile,
/ alloy element for material (density of portable electronics,
Magnesium aluminum, lead, zinc, about 2/3 of that of appliances, power
Alloys and other nonferrous aluminum), strong and tools, sporting goods
alloys; alloyed with tough, good corrosion parts, and aerospace
aluminum to improve resistance, easily cast. equipment.
the mechanical,
fabrication, and welding
characteristics.
Nickel / Pure metal / Alloys very Very good corrosion The major use of
Nickel Alloys well with large amounts resistance (can be nickel is in the
of other elements, alloyed to extend preparation of alloys
chiefly chromium, beyond stainless or plating - and to
molybdenum, and steels), good high improve corrosion
tungsten. temperature and resistance;
mechanical applications include
performance, fairly electronic lead
good conductor of wires, battery
heat and electricity. components, and
heat exchangers in
corrosive
environments.
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Titanium / Pure metal / Easily Low density, low Aerospace
Titanium alloys with aluminum, coefficient of thermal structures and other
Alloys nickel, chromium, and expansion, high melting high-performance
other elements. point, excellent corrosion applications,
resistance, nontoxic and chemical and
generally biologically petrochemical
compatible with human applications, marine
tissues and bones, high environments, and
strength, stiffness, good biomaterial
toughness. applications.
Zinc / Zinc Pure metal/ Metal is Excellent corrosion Used principally for
Alloys employed to form resistance, light weight, galvanizing iron
numerous alloys with reasonable conductor of (more than 50% of
other metals. Alloys of electricity. metallic zinc goes
primarily zinc with into galvanizing
small amounts of steel), numerous
copper, aluminum, automotive
and magnesium are applications because
useful in die-casting. of its light weight.
The most widely used
alloy of zinc is brass.
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