What?: Class T05 and T06 - Foundry Fundamentals

Machine
NTI - DEMITranslated by Google
DEMI
Industrial Technology Center
Introduction to Mechanical Technologies and Processes

Class T05 and T06 - Foundry Fundamentals
Miguel A. Machado
Telmo G. Santos
J. Pamies Teixeira
What?
- What is the Foundry Process?
- What kind of products can you produce?
- In what materials?
- What are the variants of the foundry process?
- What are your technological principles?
- What is the microstructure of a casting?
- How to characterize the flow of liquid metal?
- How can the solidification time be estimated?

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NTI - DEMI Translated by Google
ITPM: Discipline Program
• Materials:
- Know the main engineering materials and their basic properties:
Metals (ferrous and non-ferrous)
Polymers (thermoplastics, thermosets, elastomers)
ceramics
- Foundry
Composites (MMCc, CMCc, PMCs) - Pulverotechnology
- Processing of polymers
(Moulding, Injection, Insufflation…)
- Forging
- Extrusion
• Technological processes - Rolling
- Bending
- Basic operating principle; - Stamping
- Main parameters and types of defects; - Calendering
- Types of materials possible to process; - Machining

- Turning
- Types of products (geometries / properties) obtained; - Break-in cutting, Drilling
- Equipment - Rectification
- thermal cut
- Welding
(MIG, TIG, ER, Laser, SFL…)
- Brazing -
Adhesives
• Quality control
- Mechanical connection (Riveted / Screwed)
- Metrology
- Destructive and Non-Destructive Testing - Other / special processes
(Coatings, Rapid Prototyping…)
- Normalization
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Classification of Mechanical Processes
Possible classification based on physical principles:
on the plate
Friction
+ plastic
Deformation deformation
in the mass
Mechanics
chip start
Friction
+
Deformation Cut
+
Fracture
Law Suit break-in
Technological
(Metals)
Switzerland,
swissSteel 2008
AG,
Welding
Fusion
thermal +
Solidification
Foundry
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NTI - DEMI Translated by Google
Possible classification based on primary and secondary operations (MF Ashby):
Material
Foundry molding Plastic Pulverotechnology Special

processes
of
primaries
modeling
(permanent, non- (polymer, glass) (applied to metallic Processes

permanent, Deformation and ceramic
green sand, injected molds) (forging, materials) (CVD, electroforming,
hand lay-up)
extrusion, rolling, stamping, calendering)
Cutting Connection
Treatments
secondary
modeling
(machining, (Thermal)
processes
of
turning, (soldering, brazing, (quenching,

plucking, bolting, riveting, tempering,
grinding) adhesives) aging, mechanical work)
finishing processes
of
Finishing
(polishing,
electroplating, anodizing, painting)
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Metals
Classification in Processing and Linking Operations (MP Groover): polymers

ceramics composites
Casting, Molding… s s No s
Modeling Pulverotechnology s s
processes
plastic deformation s NNNo
operations of Cutting (material removal) s s

Processing Improvement
of properties mec.
Thermal treatments YN NN
Processing
Cleaning and super treatments. s s
surfaces
Suit
Law
Mechanics
Coatings and deposition s
Welding s NNN
link
remains brazing s NNN
operations of bonding by stickers SSSS

Connection
bolted connection SSSS

mechanical connection
riveted connection SS s
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Possible classification based on the final result obtained:
Liaison Processes
+ =
Court Processes
- =
Deformation Processes
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Foundry Technology - Definition

Give examples of industrial
products typically obtained by
the casting process.
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Give examples of industrial products typically
obtained by the casting process.
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Typical Foundry Components
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https://www.youtube.com/watch?v=rsBbt3TxKGg
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Foundry Processes
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What do you understand by
Foundry Technology?
“The foundry technology is composed of methods, processes and techniques

for forming molten metals, and for controlled solidification”.
The fundamental objective of foundry is to give the metal a suitable geometric shape,
pouring it in the molten state inside a cavity made inside a molding (set of elements
in appropriate materials that define the mould), so that after solidification it is
obtained the molded part.
This technique consists of the application, pure and simple, of the classical principle of
Archimedes:
“The liquid takes the shape of the vessel that contains it”
Foundry technology is one of the metal forming processes that allows the greatest
freedom of shapes, with the advantage of optimizing the economic factor, as it is
the shortest path between the raw material and the final shape of the product.
Compared to other technological processes, foundry is typically more economical,

the more complex the geometry of the parts.
All metallic products necessarily go through the solidification process.
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• What are the main variants of the Foundry process? •
What is the criteria for your classification?
Process framing Model

1) Green sand casting lost Permanent
2) Shell molding lost Permanent
3) Lost wax casting lost Lost
4) Die Casting Permanent -
5) Centrifugal Casting Permanent -
6) Squeeze casting Permanent -
7) Other Processes / variants - -
• What are the basic operating principles of each of these processes?

What steps do they involve?
• What are the main application domains of each of the processes of

foundry, its advantages and disadvantages?
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1) Green sand casting
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Foundry Technology
Green sand casting
sand casting
Moldings obtained by compacting a mixture

of sand with agglomerates, additives, and a
certain percentage of moisture, known
as “green sand” molding.
Generally, the molding material consists of a
mixture of silica sand and clay, with
the latter acting as a binder.
It is this molding that serves as a mold:

a negative shape of the volume of the
part to be poured.
The mold cavity, in turn, is obtained through a model, which generally has the shape
of the part with a higher geometric scale to compensate for the contraction
phenomenon during solidification. The model must also show excess thicknesses in
the machining areas.
The model can be made of wood, plastic or metal.

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Foundry Technology
Green sand casting
sand casting
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Foundry Technology
Green sand casting
https://youtu.be/pwaXCko_Tkw?t=71 sand casting
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Foundry Technology
Green sand casting
sand casting
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Foundry Technology
Green sand casting
sand casting
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Foundry Technology
Green sand casting
The Process (1/2) sand casting
Model (wood) Preparation of Males (sand) Molding Box
filling of Place the other half

Sprinkle with talcum powder
Molding Box of the model
Filling of the 2nd

template removal Placement of Males
Molding Box
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Foundry Technology
Green sand casting
The Process (2/2) sand casting
Leak demolding
Removal of Males final casting

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Foundry Technology
Male framing sand molding
male + framing
https://www.youtube.com/watch?v=M95bhPrDwA0
Feeding bowl and

breather channel
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Foundry Technology
General rules for foundry
• Design the part in a way that allows easy pouring.
• Select a process and material suitable for the

component, its size and properties, etc.
• Define and locate the parting line on the part.
• Locate and design the feed channels so that

allow uniform flow and quiet filling of the molding cavity.
• Define the proper geometry of the feedways.
• Properly locate the feeder spouts
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Foundry Technology
Location and Design of Feeding
Channels
• When parts have a large volume, multiple ports are preferable.
• Feed ports must feed the cavity at the most

thick.
• The feedways must have smooth transitions in the cavity zone (placement
of fillets) to avoid turbulence in the flow.
• The feed channel closest to the sprue must be of adequate length to

allow its removal after solidification.
• The minimum length of the feed channels must be 3 to 5 times the

channel diameter, depending on the metal to be cast.
• Curved feedways should be avoided, but when this is unavoidable,

next to the molding there should be a straight section.
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Foundry Technology
Rules for Designing Feeders
• The feed spout must never solidify before the casting.
• The volume of the sprue must be sufficient to provide the amount of

molten metal necessary to compensate for shrinkage of the part
in the mold cavity.
• The joints between the casting and the feeders must not constitute
hot spots where porosities due to shrinkage can
to occur.
• Guts must be properly located to ensure that the metal

liquid is delivered where it is needed most.
• The manometric height of the spout and the sections of the channels must prevent the
formation of pores and voids. There must be enough pressure to
ensure that the molten metal reaches all locations in the mold cavity.
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Foundry Technology
lost-foam casting
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Foundry Technology
automatic line sand casting
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Foundry Technology
2) Shell molding
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Foundry Technology
Creation of a Foundry “Shell Molding”
permanent model
Fixing the model to a

metal plate
Fixation to a box with sand

pre-coated with resin.
Rotation of the box and
gravity fall of the sand
on the model.
Formation of half molding
Joining the half moldings

and pouring the material
Extraction of parts
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Foundry Technology
Foundry “Shell Molding”
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Foundry Technology
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Foundry Technology
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Foundry Technology
Benefits
• Greater accuracy,
• Closer dimensional tolerances
tight, •
Greater shape accuracy
• Less surface roughness •
Manufacturing speed
• Reduction in the volume of
molding
sands • Storage capacity of the
shells
Disadvantages
• Light moldings •
• Higher cost of pre-coated sands • Higher
More economical process than those of
cost of model plates • Limitation of the
sand for series production of parts
process to small and medium-sized pieces
(mechanical strength of the shells)
• Sands that are not economically recyclable
• Minimum thickness obtained of 6 mm

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Foundry Technology
3) Lost wax casting
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Foundry Technology
lost wax casting
Lost Wax asting or Investment casting
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Foundry Technology
lost wax casting
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Foundry Technology
lost wax casting
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Foundry Technology
lost wax casting
http://www.youtube.com/watch?v=WXFRRg8YMT0
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Foundry Technology
lost wax casting
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Foundry Technology
lost wax casting
Application domains: - Range of Lost Wax asting or Investment casting
metallic alloys: Those typical of foundry processes; - Range of
dimensions and weight: Typically less than 2-3 kg (up to ~50 kg); - Ability to
obtain minimum thicknesses: It is possible to obtain thicknesses of the order of 1
mm; - Replica of details: Good replica of details and shape. The practice of pre-
heating moldings increases this property.
Benefits:
- Greater precision, tighter dimensional
tolerances, greater shape accuracy;
- Lower surface roughness;
- Minimum thicknesses lower than those
obtained by Shell Molding;
Disadvantages: -
Small and medium-sized pieces; -
Lengthy and demanding process of
obtaining the models.
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Foundry Technology
4) Injected casting
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Foundry Technology
die casting
metal injection molding
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Foundry Technology
die casting
http://www.youtube.com/watch? metal injection molding
v=W6 VgCaRozq8&feature=related
The metallic molds used in die casting (under pressure) are called dies.
The matrix is made of heat-treated tool steel, with two parts that are hermetically sealed before
pouring the liquid metal.
Metal is injected into the die cavity under sufficient pressure to completely fill all of its spaces and
mold cavities. Pressure is maintained until the metal solidifies.
Subsequently, the matrix is opened and the part is ejected.
The matrices can have forced cooling, avoiding their overheating, and consequently their useful
life.
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Foundry Technology
die casting
Die casting is one of the processes based on permanent moulding. These have the
following advantages over non-permanent impressions:
- Higher production speed;
- Greater dimensional accuracy and less roughness of the pieces obtained;
- Better defined pieces (sharp edges), being able to obtain more complex shapes;
- Better quality parts and greater uniformity due to the cooling process;
- Savings in pouring material: i) less loss in spouts and feeders, ii) less loss in excess
thicknesses for finishing, iii) fewer rejected parts;
- Cleaner workshops and space saving;
Drawbacks:
- Higher initial molding cost, which requires larger series; -
Limited to alloys with relatively low melting points; -
More limited weight and dimensions.
Attributes required for cast alloys:

- Relatively low melting point; -
Good
fluidity; - Innocuous for molding and injection machines;
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Foundry Technology
die casting
Typical Properties and Applications of Die Casting Alloys
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Foundry Technology
5) Centrifugal Casting
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Foundry Technology
horizontal centrifugal casting
In this casting process, the shape of the

surface of the part derives from the
centrifugation itself, being therefore
cylindrical and the thickness determined by
the amount of
cast material. This is the case of tubes cast
by centrifugation, which therefore do not require cores.
https://youtu.be/iUjOhtXCoro
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Foundry Technology
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Foundry Technology
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centrifugal casting
Vertical
Pressure casting due to centrifugation: In this

process, the axis of rotation is outside the part. To ensure balance, equal
and symmetrically arranged pieces are required.
http://www.youtube.com/watch?v=3qKGx_AxHp0
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Foundry Technology
Vertical centrifugal casting
Pressure casting due to centrifugation: In

this process, the axis of rotation is outside the part. To ensure balance, equal and
symmetrically arranged pieces are required.
http://www.youtube.com/watch?v=3qKGx_AxHp0
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Foundry Technology
Surprise!...
How is a chocolate bunny (or egg)

produced?
Note that:
- It is
hollow; - It has no opening to the
outside; - Males are not
used; - No collages.
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Foundry Technology
Investigate…
On the outer surface there are molding marks, but not inside!…
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Foundry Technology
The thickness is not uniform and the interior looks like a

fluid-free surface or a “meniscus”…
…Generalizing centrifugal casting to 3D…
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Foundry Technology
Conclusion:
Chocolate rotational melting!
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Foundry Technology
https://www.youtube.com/watch?v=lAQYfJAuw5M
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Foundry Technology
Rotational casting: other
applications
Used in large pieces of

the “shell” type.
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Foundry Technology
6) Squeeze casting
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Foundry Technology
Squeeze Casting
Pressure casting "Squeeze Casting",

also known as "liquid metal forging", is a
process in which the metal cast in the liquid
state is solidified, under pressure, inside
a metallic die closed by a punch.
CAPABILITIES AND
LIMITATIONS Advantages: - Little waste of

material, no need for
finishing, better mechanical characteristics,
easily automatable.
Limitations:
- The limiting factors are related to the
maximum pressure
capacities and the dimensional characteristics
of the required presses.
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Squeeze casting (by forming)
Pressure casting "Squeeze Casting", also known as "liquid metal forging", is a process in which
the metal cast in the liquid state is solidified, under pressure, inside a metallic die closed by a punch.
http://www.youtube.com/watch?v=CYXUfXsDh5I
CAPABILITIES AND
LIMITATIONS Advantages: - Little waste of material, no need for

finishing, better mechanical characteristics, easily automatable.
Limitations:
- The limiting factors are related to the maximum pressure capacities
and the dimensional characteristics of the required presses.
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Squeeze casting (by forming)
http://www.youtube.com/watch?v=CYXUfXsDh5I
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Foundry Technology
Comparison between Processes
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Foundry Technology
The Different Processes
Process Benefits Limitations
Sand Weak finish and dimensional accuracy.

Almost all materials with no size limit
Requires finishing operations
Shell
Good dimensional accuracy and good finish Size limitations and higher costs
molding
Mold. Complex shapes. Precision and good limited size
ceramics finish
Parts size. High costs. Limited to materials

lost wax Complex shapes. Excellent finish. with a lower melting temperature than molding.
Mold. Good finishes and precision. A lot High cost of moldings. Moderate complexity.
permanent of productivity low melting point materials
Fund. High precision and excellent finish. High mold costs. Size somewhat limited.
injected High productivity Not suitable for ferrous materials
Fund. High equipment cost and form limitation.
Large tubular components
centrifuge
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General features
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Foundry Technology
Calculation
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Foundry Technology
Molten Metal Flow
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Foundry Technology
Molten Metal Flow
Bernoulli's Equation: It is based on the principle of conservation of

energy: h – elevation height of the
2 molten metal p – pressure
ph ÿ v ÿ constant
within the liquid v – flow velocity
ÿ ÿ g 2g
Law of continuity (conservation of mass): Q ÿ A1v1 ÿ A2v2
Outflow features:
vDÿ ÿ – viscosity
Turbulence control (flow must be calm) – Re ÿ ÿ – density
Reynolds number ÿ D – channel diameter
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Foundry Technology
Molten Metal Flow
From Bernoulli Equation + Continuity Law:
Sizing of Gitos and Channels:

The increase in speed decreases the pressure, with a tendency for air aspiration.
The conical spout allows this control.
TO 1 h2
ÿ
A2 h1
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Foundry Technology
Heat Transfer Phenomena
All heat exchanges are the result of heat flow through and along the
entire molding-part structure.
Temperature distribution at the mold wall and at the metal-liquid

Chvorinov's rule
interface during solidification
= ÿ V ÿn
CT ÿ ÿ
ÿÿ A
T - Solidification time
V - Volume of leaked material
A - Surface area
C is a constant that reflects: (a) the molding

material; (b) the properties of the molten
metal; (c) the pouring temperature.
The n parameter has an empirical value of

1.5 to 2, with 2 being more usual.
(by doubling the solidification time the wall thickness 2

ÿ1.41
solidified increases times)
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Solidification Time
Carapace solidified in a piece of steel. The residual liquid was removed after the indicated times.
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Foundry Technology
Other Aspects of Foundry
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Foundry Technology
Typical Cast Metal Shrinkage
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Foundry Technology
To have in count...
Metal solidification
• Pure metal or
Condition the metallurgical aspects and the
alloy • Alloy final micro structures
composition • Cooling rate
Flow of molten material

• Pressures •
Condition the feed channels
Speeds • Melt
(Gitos) and feeders
viscosity
Influence of Cast Material and Molding •

Physical Properties of Cast Material
Condition the thermal phenomena
• Physical Properties of Moldings
• Geometry and Complexity of the Final Part
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Foundry Technology
Solidification of pure metals
Pure metals have a well-defined melting point (Al 660 ºC; Fe 1537
ºC; Tungsten 3410 ºC)
Solidify at constant temperature (Latent heat)
During solidification there is a variation of specific mass due to
volume contraction.
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Foundry Technology
solidification of alloys
Illustration of three casting structures: (a) columnar dendritic; (b) equiaxed dendritic; (c) non-dendritic.
Depending on the cooling speed there will be micro segregation: the composition on the
surface of the dendrites is different from the composition inside.
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Foundry Technology
Structures
Preferential textures on the surface in contact with the

molding (epitaxy). Only favorably oriented grains grow from
the wall inwards.
Schematic illustration of 3 square mold cast structures

(a) pure metals;
(b) alloys in solid solution;
(c) Structure obtained with the addition of nucleating agents
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Foundry Technology
typical defects
hot cracking
These defects occur due to the fact that the part cannot contract freely, due to the
constraints imposed by the different areas of the molds and cores. Placing hot zones in
moldings can prevent these effects.
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Foundry Technology
typical defects
Miscellaneous defects that result from problems in the preparation of
moldings, from poor sizing of the feeding system.
bubbles empty porosities cold knuckles insufficient food
Penetration misalignment of molds sucks

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Foundry Technology
Directional Solidification and
Mono crystal growth applied
to turbine blades
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Foundry Technology
to turbine blades
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Foundry Technology
to turbine blades
These turbine blades have had their surfaces etched with acid to reveal their inner structure.
The one at the far right is a single crystal, the one in the middle is directionally
solidified, and the one at the left is made up of small crystal grains, with numerous boundaries.
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Foundry Technology
Monocrystal Growth Methods
crystal pulling method
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Foundry Technology
Monocrystal Growth Methods
floating
zone
method
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Machine

NTI - DEMITranslated by Google

Industrial Technology Center

Introduction to Mechanical Technologies and Processes

- What kind of products can you produce?

- What are the variants of the foundry process?

- What are your technological principles?

- What is the microstructure of a casting?

- How to characterize the flow of liquid metal?

- How can the solidification time be estimated?

ITPM: Discipline Program

- Types of materials possible to process; - Machining

Classification of Mechanical Processes

Possible classification based on physical principles:

Classification of Mechanical Processes

Possible classification based on primary and secondary operations (MF Ashby):

Foundry molding Plastic Pulverotechnology Special

(permanent, non- (polymer, glass) (applied to metallic Processes

turning, (soldering, brazing, (quenching,

Classification of Mechanical Processes

Classification in Processing and Linking Operations (MP Groover): polymers

operations of Cutting (material removal) s s

operations of bonding by stickers SSSS

bolted connection SSSS

Classification of Mechanical Processes

Possible classification based on the final result obtained:

Foundry Technology - Definition

Foundry Technology - Definition

Foundry Technology - Definition

Foundry Technology - Definition

Foundry Technology - Definition

Foundry Technology - Definition

Foundry Technology - Definition

“The foundry technology is composed of methods, processes and techniques

Compared to other technological processes, foundry is typically more economical,

Foundry Technology - Definition

Process framing Model

• What are the basic operating principles of each of these processes?

• What are the main application domains of each of the processes of

Foundry Technology - Definition

1) Green sand casting

Moldings obtained by compacting a mixture

It is this molding that serves as a mold:

The model can be made of wood, plastic or metal.

Model (wood) Preparation of Males (sand) Molding Box

filling of Place the other half

Filling of the 2nd

Removal of Males final casting

Feeding bowl and

• Design the part in a way that allows easy pouring.

• Select a process and material suitable for the

• Define and locate the parting line on the part.

• Locate and design the feed channels so that

• Define the proper geometry of the feedways.

• Properly locate the feeder spouts

• When parts have a large volume, multiple ports are preferable.

• Feed ports must feed the cavity at the most

• The feed channel closest to the sprue must be of adequate length to

• The minimum length of the feed channels must be 3 to 5 times the

• Curved feedways should be avoided, but when this is unavoidable,

• The feed spout must never solidify before the casting.

• The volume of the sprue must be sufficient to provide the amount of