Professional Documents
Culture Documents
Marvin Intern
Marvin Intern
AUGUST 2023
DECLARATION
I MARVIN KAKINDA, do declare to the best of my knowledge, that this report is originally
mine; it is a true record of the work I undertook during my industrial training at Mawakato
Technical Services and has never been submitted for the award of the Degree of Bachelor of
Science in Mechanical Engineering or any other academic qualification to Makerere
University or any other University or academic institution of higher learning
Signature: ………………………….
Date: ……………………………….
APPROVAL
This is to certify that this industrial training report is for MARVIN KAKINDA and was
carried out under our supervision during his industrial training at Mawakato Technical
Services and its ready for submission to Makerere University, Department of Mechanical
Engineering after our approval:
The production of this report and my industrial training would not have been such a great
success without the help of a number of people who went out of their way to make my stay at
Mawakato Technical Services comfortable.
I thank Makerere University, particularly the department of Mechanical Engineering and the
faculty of Engineering, for giving me the theoretical knowledge that I applied during the
course of industrial training.
I thank the management of Mawakato Technical Services, through the Human Resource
Department for granting me the opportunity to pursue my Industrial training as a partial
fulfilment of the requirement for the Bachelor of Mechanical Engineering.
Lastly, I humbly extend my sincere gratitude to my supervisor Mr. Edmund Tumusime for
his effort and supervision during the industrial training.
May God richly bless you all and reward you abundantly.
ABSTRACT
Since the discovery of the earth’s minerals, metal casting process has played an important
role in society. An integral part of every technological advance, castings have allowed us to
build equipment to feed our people, fight for democracy, build infrastructure and manufacture
cars, trains, and airplanes. In general, castings have been and will continue to be the key
ingredient in the recipe for a better way of life. There are various types of casting processes,
such as sand-casting, permanent-mold casting, investment casting and die-casting. Casting is
the process of producing components through molten metal pouring into mold cavity. Not
many developments in recent decades have changed the understanding of the metal casting
process as fundamentally as casting process. The main intention of this internship report is to
provide an easy to read and attractive overview of metal casting process, applications of
process, types of cores used in casting and the activities I carried out types.
TABLE OF CONTENT
DECLARATION.......................................................................................................................ii
APPROVAL.............................................................................................................................iii
ACKNOWLEDGEMENT........................................................................................................iv
ABSTRACT...............................................................................................................................v
TABLE OF CONTENT............................................................................................................vi
TABLE OF FIGURES..............................................................................................................ix
CHAPTER 1: GENERAL INTRODUCTION...........................................................................1
1.1 Background of Industrial Training.............................................1
1.2 Industrial Training Objectives....................................................1
1.2.1 General objectives...............................................................1
1.2.2 Specific objectives...............................................................1
1.3 Background of Mawakato Technical Services...........................1
1.4 Company Location.....................................................................1
1.5 Vision..........................................................................................2
1.6 Mission.......................................................................................2
1.7 Clientele of Mawakato Technical Services................................2
1.8 Organization Structure of Mawakato Technical Services Ltd....2
1.9 Scope of Company Activities.....................................................3
1.10 Components Made at Mawakato Technical Services Limited. 3
CHAPTER 2: INTRODUCTION TO METAL CASTING.......................................................4
2.1 Introduction to Metal Casting.....................................................4
2.2 Metal Casting History.................................................................4
2.3 Casting Terms:............................................................................4
2.4 Types of Casting used at Mawakato Technical Services...........5
2.5 Sand Casting...............................................................................5
3.2.1 Process Cycle.......................................................................6
3.3 Investment Casting.....................................................................8
3.3.1 Creating the Mould..............................................................8
3.4 Die Casting.................................................................................9
4.1 Terminology Used in Sand Moulding......................................10
4.2 Tools Used in Sand Moulding..................................................10
4.2.2 Riddle.................................................................................10
4.2.3 Rammers............................................................................11
4.2.4 Trowels..............................................................................11
4.2.6 Vent Wire..........................................................................11
4.2.7 Lifter..................................................................................11
4.2.10 Sprue Cutter.....................................................................11
4.2.13 Sprit Level.......................................................................11
5.2 Properties of Moulding Sand....................................................12
CHAPTER 3: THE ACTIVITIES I CARRIED OUT AND SWOT ANALYSIS OF
MAWAKATO TECHNICAL SERVICES..............................................................................13
The Activities I Carried Out...........................................................13
3.1 Introduction..........................................................................13
3.2 Preparing the Tilting Furnace for Melting Cast Iron............14
3.3 Preparing the ladle and the molds for pouring.....................19
3.4 Preparing the molds for pouring...........................................20
SWOT ANALYSIS OF MAWAKATO TECHNICAL SERVICES
........................................................................................................20
3.5 Introduction..........................................................................20
3.6 Strengths...............................................................................21
3.7 Weaknesses...........................................................................21
3.8 Opportunities........................................................................22
3.9 Threats..................................................................................22
CHAPTER 4: OBSERVATIONS, SKILLS ACQUIRED, CHALLENGES FACED,
RECOMMENDATIONS AND CONCLUSION.....................................................................23
4.1 Observation...............................................................................23
4.2 Experience gained/achievements from the training..................23
4.3 Challenges faced during the training........................................23
4.4 Recommendations....................................................................23
4.5 Conclusion................................................................................24
TABLE OF FIGURES
Figure 1: parts of mold..............................................................................................................6
Figure 2: Process Cycle for Casting...........................................................................................9
Figure 3: Investment Casting...................................................................................................10
Figure 4: Die Casting...............................................................................................................12
Figure 5: Riddle........................................................................................................................14
Figure 6: Trowel.......................................................................................................................14
Figure 7: Vent wire..................................................................................................................14
Figure 8: Lifter.........................................................................................................................14
Figure 9: Sprue cutter...............................................................................................................14
Figure 10: Spirit Level.............................................................................................................14
Figure 11: Pattern.....................................................................................................................19
Figure 12: Ramming................................................................................................................19
Figure 13: Levelling the sand...................................................................................................19
Figure 14: Placing the pattern in mold box..............................................................................19
Figure 15: metal plates.............................................................................................................20
Figure 16: Placing metal plates in tooth gaps..........................................................................20
Figure 17: Putting dry sand......................................................................................................20
Figure 18: Placing the top mold box and pipe.........................................................................20
Figure 19: Putting fine sand around pattern.............................................................................21
Figure 20: Adding sand and ramming......................................................................................21
Figure 21: Putting position pins...............................................................................................21
Figure 22: Putting vents...........................................................................................................21
Figure 23: Removing pattern...................................................................................................22
Figure 24: Mold ready..............................................................................................................22
Figure 25: Preparing the Ladle.................................................................................................24
Figure 26: Ladle is ready..........................................................................................................24
CHAPTER 1: GENERAL INTRODUCTION
1.1 Background of Industrial Training
Industrial attachment is an industrial based practical training experience that prepares
students for the tasks they are expected to perform on completion of their training.
1.5 Vision
To be the leading provider of high-quality foundry products and services in order to fulfil the
customers’ desires.
1.6 Mission
To assist in developing technology base of the micro and small-scale enterprises (MSEs)
sector and enabling the growth of such enterprises.
BOARD OF DIRECTORS
MANAGING
DIRECTOR
OPERATIONS
MANAGER
SECRETARY DRIVER
At Mawakato, the following methods are commonly used for casting metallic components as
per customer’s specifications.
Sand casting
Die casting
Investment casting
The metals normally used for the casting process are Aluminium, Cast iron, Brass, Bronze,
and Copper. These metals are obtained in the form of scrap from nearby scrap depots within
the suburb of the company premises.
Through the metal casting process, molten metal is poured into a mold that matches the final
dimensions of the finished product. While all metals can be cast, the most predominant are
iron, aluminum, steel, and copper-based alloys. Castings range in weight from less than an
ounce to single parts weighing several hundred tons. Over the years, the development of the
metal casting industry paralleled the American industrial revolution and foundries developed
near growing settlements and cities nationwide. As settlers plowed through the American
prairie, stronger metals were required to cut through the turf, shoe horses, create buggies and
eventually lay the rail tracks that opened the west. Today, iron castings are found in almost
all durable goods and machinery. From the machines that make the vehicles we drive to the
materials found in our homes, we live and travel on cast iron.
2.3 Casting Terms:
1) Flask: A metal or wood frame, without fixed top or bottom, in which the mold is
formed. Depending upon the position of the flask in the molding structure, it is
referred to by various names such as drag – lower molding flask, cope – upper
molding flask, cheek – intermediate molding flask used in three-piece molding
2) Pattern: It is the replica of the final object to be made. The mold cavity is made with
the help of pattern.
3) Parting line: This is the dividing line between the two molding flasks that makes up
the mold.
4) Molding sand: Sand, which binds strongly without losing its permeability to air or
gases. It is a mixture of silica sand, clay, and moisture in appropriate proportions.
5) Facing sand: The small amount of carbonaceous material sprinkled on the inner
surface of the mold cavity to give a better surface finish to the castings.
6) Core: A separate part of the mold, made of sand and generally baked, which is used
to create openings and various shaped cavities in the castings.
7) Pouring basin: A small funnel shaped cavity at the top of the mold into which the
molten metal is poured.
8) Sprue: The passage through which the molten metal, from the pouring basin, reaches
the mold cavity. In many cases it controls the flow of metal into the mold.
9) Runner: The channel through which the molten metal is carried from the sprue to the
gate.
10) Gate: A channel through which the molten metal enters the mold cavity.
11) Chaplets: Chaplets are used to support the cores inside the mold cavity to take care of
its own weight and overcome the met allostatic force.
12) Riser: A column of molten metal placed in the mold to feed the castings as it shrinks
and solidifies. It is also known as “feed head”.
13) Vent: Small opening in the mold to facilitate escape of air and gases
The process uses a mold that’s made of silica-based materials, such as naturally-bonded or
synthetic sand to form the smooth mold surface. The mold surface has 2 parts, cope (the
upper half) and drag (the lower half). Molten metal is poured into the pattern using a pouring
cup and left to solidify to take the final shape. Finally, trimming off extra metal is done for
the finishing of the final metal casting product.
1. Mold-making
The first step in the sand-casting process is to create the mold for the casting. In an
expendable mold process, this step must be performed for each casting. A sand mold is
formed by packing sand into each half of the mold. The sand is packed around the pattern,
which is a replica of the external shape of the casting. When the pattern is removed, the
cavity that will form the casting remains. Any internal features of the casting that cannot
be formed by the pattern are formed by separate cores which are made of sand prior to the
formation of the mold. Further details on mold-making will be described in the next
section. The mold-making time includes positioning the pattern, packing the sand, and
removing the pattern. The mold-making time is affected by the size of the part, the
number of cores, and the type of sand mold. If the mold type requires heating or baking
time, the mold-making time is substantially increased. Also, lubrication is often applied to
the surfaces of the mold cavity in order to facilitate removal of the casting. The use of a
lubricant also improves the flow of the metal and can improve the surface finish of the
casting. The lubricant that is used is chosen based upon the sand and molten metal
temperature.
2. Clamping
Once the mold has been made, it must be prepared for the molten metal to be poured. The
surface of the mold cavity is first lubricated to facilitate the removal of the casting. Then,
the cores are positioned, and the mold halves are closed and securely clamped together. It
is essential that the mold halves remain securely closed to prevent the loss of any
material.
3. Pouring
The molten metal is maintained at a set temperature in a furnace. After the mold has been
clamped, the molten metal can be ladled from its holding container in the furnace and
poured into the mold. The pouring can be performed manually or by an automated
machine. Enough molten metal must be poured to fill the entire cavity and all channels in
the mold. The filling time is very short in order to prevent early solidification of any one
part of the metal.
4. Cooling
The molten metal that is poured into the mold will begin to cool and solidify once it
enters the cavity. When the entire cavity is filled and the molten metal solidifies, the final
shape of the casting is formed. The mold cannot be opened until the cooling time has
elapsed. The desired cooling time can be estimated based upon the wall thickness of the
casting and the temperature of the metal. Most of the possible defects that can occur are a
result of the solidification process. If some of the molten metal cools too quickly, the part
may exhibit shrinkage, cracks, or incomplete sections. Preventative measures can be
taken in designing both the part and the mold and will be explored in later sections.
5. Removal
After the predetermined solidification time has passed, the sand mold can simply be
broken, and the casting removed. This step, sometimes called shakeout, is typically
performed by a vibrating machine that shakes the sand and casts out of the flask. Once
removed, the casting will likely have some sand and oxide layers adhered to the surface.
Shot blasting is sometimes used to remove any remaining sand, especially from internal
surfaces and reduce the surface roughness.
6. Trimming
During cooling, the material from the channels in the mold solidifies attached to the part.
This excess material must be trimmed from the casting either manually via cutting or
sawing or using a trimming press. The time required to trim the excess material can be
estimated from the size of the casting's envelope. A larger casting will require a longer
trimming time. The scrap material that results from this trimming is either discarded or
reused in the sand-casting process. However, the scrap material may need to be
reconditioned to the proper chemical composition before it can be combined with non-
recycled metal and reused.
Advantages Disadvantages
Recycling ability
Once the sprues are filled with the mould attachments, they are dipped into a cleaning bath to
ensure the future layers of shell cling to the mould profile correctly. Before the first layer of
the shell is added the sprue assembly is dipped into a bath of slurry, this will form the
bonding agent to the layer of ceramic powder which is added in either a rainfall sander or a
fluidized sand bed, this process gradually builds up a ceramic shell around the moulds and
sprue, with progressively coarser layers of ceramic coating being added over several coats
until the desired shell thickness is achieved.
After the ceramic thickness is achieved the sprue along with its moulds are oven baked to
both harden the ceramic shell and to melt all of the wax from within it, this will include all of
the wax moulds and the wax sprue leaving a hollow ceramic shell. The wax moulds once
melted leave a perfect void of the desired mould to be cast, the sprue once melted leaves open
channels for the liquid metal to flow and fill all of the hollow shell. The molten metals are
poured into the now hollow ceramic shell via the filling cup and left to cool off. Once the
metal has cooled sufficiently the ceramic shell is broken up by either being submitted to
vibrations or a water jet.
Advantages Disadvantages
Due to breaking away of the shell mold, it allows New die requirement for the creation of
for castings with 90-degree angles wax patterns for each casting cycle
There are two types of pressure die casting depending on the pressure. Namely, the low-
pressure die casting and the high-pressure die casting. High pressure die casting is more
popular for mass production of complex geometries that require high precision. Whereas, for
large and simple parts production, low-pressure die casting is a preferable casting process.
In this type of metal casting, non-ferrous metals, and alloys such as zinc, tin, copper, and
aluminum are injected into a reusable mold coated with a lubricant at high pressure. Thus,
high pressure is maintained throughout the rapid injection process to avoid metal hardening.
Finally, after completion of the process, extraction of casting and finishing takes place to
remove any excess material.
Advantages Disadvantages
Rapid cooling of molten metal pertaining Complete setup requires a large capital
to faster production rates investment
4.2.3 Rammers
A rammer is a wood or metal tool used for ramming or packing the sand in the moulding box.
4.2.4 Trowels
A trowel is used for finishing and repairing a mold. It consists of a metal-flat with different
shapes and wooden handles. It is also used for smoothening the moldy surfaces, shaping the
square corners, finishing the parting surfaces. It is available in different shapes like
rectangular, triangular, square, round etc.,
4.2.7 Lifter
A lifter is used for picking up the unwanted dust and damaged parts of the mould. It is an L
shaped steel tool with long holding shank and a small toe. It is available in thin sections of
various widths and lengths, according to the shape of the mould.
1) Porosity: Porosity also known as permeability is the most important property of the
moulding sand. It is the ability of the moulding sand to allow gasses to pass through.
Gasses and steam are generated during the pouring of molten metal into the sand
cavity. This property depends not only on the shape and size of the particles of the
sand but also, on the amount of the clay, binding material, and moisture contents in
the mixture.
2) Cohesiveness: Cohesiveness is the property of sand to hold its particles together. It
may be defined as the strength of the moulding sand. This property plays a vital role
in retaining intricate shapes of the mould. Insufficient strength may lead to a collapse
in the mould particles during handling, turning over, or closing. Clay and bentonite
improves the cohesiveness.
3) Adhesiveness: Adhesiveness is the property of sand due to which the sand particles
sticks to the sides of the moulding box. Adhesiveness of sand enables the proper
lifting of cope along with the sand.
4) Plasticity: Plasticity is the property of the moulding sand by virtue of which it flows
to all corners around the mould when rammed, thus not providing any possibility of
left out spaces and acquires a predetermined shape under ramming pressure.
5) Flow-Ability: Flow-ability is the ability of moulding sand to free flow and fill the
recesses and the fine details in the pattern. It varies with moisture content.
6) Collapsibility: Collapsibility is the property of sand due to which the sand mould
collapse automatically after the solidification of the casting. The mould should
disintegrate into small particles of moulding sand with minimum force after the
casting is removed from it.
7) Refractoriness: Refractoriness is the property of sand to withstand high temperature
of molten metal without fusion or soften. Moulding sands with poor refractoriness
may burn when the molten metal is poured into the mould. Usually, sand moulds
should be able to withstand up to 1650°C.
CHAPTER 3: HANDS ON ACTIVITIES AND SWOT ANALYSIS OF MAWAKATO
TECHNICAL SERVICES
3.1 Introduction
The steps involved in making the molds are the same though it may change slightly
depending on the complexity of the part to be made. For examples for the case of gears, we
normally use metal plates by putting them in the gaps so that the sand does not break when
the pattern is removed, for some cases we use sticks in the top box in order for the extruded
parts to come out with minimal breaking.
Most of the mold making process carried out at Mawakato is ground molding. Ground
molding means that instead of using two boxes/flasks (the cope and the drag), one box (the
cope) is used and instead of using a second box, the mold is put on the ground.
After the repairing of the damaged parts of the mold, the next step is to spread graphite
powder. Then dry the molds by heating them up using charcoal.
Figure 11: Pattern Figure 12: Ramming
Figure 13: Levelling the sand Figure 14: Placing the pattern in mold
box
Figure 19: Putting fine sand around pattern Figure 20: Adding sand and ramming
3.3.2 Procedure
The covers were removed from the furnace and placed aside.
The furnace was cleaned by removing the slug and the solidified metal that had
accidentally poured out of the crucible into the furnace bottom. This process takes
some time since removing the solidified metal and slug requires repeated
knocking.
After knocking off the slug and the molten metal in the furnace, the furnace is
unlocked and tilted to a suitable angle to pour of the waste. While the furnace is
still in that position, the knocking process is continued to ensure that the furnace is
clean enough.
The crucible is also cleaned by scrubbing off the slug that had remained on the
sides of the crucible. This helps in such a way that the crucible does not get filled
up and also to avoid contamination with the molten metal.
The fire bricks that hold the crucible in position are worked upon by knocking
them from their position and fixing them back and applying red sand on them as a
bonding material to fix the bricks on the furnace and the crucible.
Red sand is mixed with sand containing graphite and little water to make a
uniform mixture. This mixture is placed on top of the crucible to account for the
Brocken parts of the crucible. This helps in such a way that when putting the
metal, the crucible gets full.
Sand mixed with graphite is put at the bottom of the furnace. This sand acts as a
layer between the actual base of the furnace and the slug plus the molten metal
that pours off inside the furnace. When this metal solidifies on the sand instead of
the actual furnace, it becomes very easy to remove during the cleaning.
The crucible is then filled with cast iron.
Red sand is the mixed with water.
The red soil around the furnace that was used in the previous melting operation is
knocked off to create room to apply another new red soil leaving fire bricks. This
added soil creates a platform for the cover and therefore it’s made in such a way
that it goes beyond the level of the added metal. Before adding new red soil, the
fire bricks on the top of the furnace are wetted to prevent them from draining
water from the red sand so easily.
The red soil is added to create the platform.
The furnace is the covered
The blower pipe and the oil pipes are connected to the furnace.
The furnace is then turned on.
Strengths
Weaknesses
Opportunities
Threats.
The internal environmental analysis can help an organization to identify its core strengths and
weaknesses. Whereas external environmental analysis can help the organization to identify
opportunities and threats that must be considered to ensure long-term business survival.
Mawakato Technical Services can adapt and control its strengths and weaknesses (internal
factors), but it cannot control the external factors (opportunities and threats):
Some examples of external factors (opportunities/threats) are- customers’ changing tastes and
interests, competitive trends, inflation, and population growth.
SWOT analysis of Mawakato Technical Services can be based to make important strategic
decisions and accomplish the business objectives. The four components of Mawakato
Technical Services SWOT analysis are given below.
3.6 Strengths
1. Expertise and Experience
Mawakato Technical Services offers a wide range of services, including casting, molding,
machining, and metal fabrication, catering to diverse customer needs.
4. Strategic Location
The company's strategic location in Uganda provides proximity to local and regional
markets, facilitating efficient distribution and customer reach.
3.7 Weaknesses
1. Limited Market Presence
2. Dependency on Suppliers
The company's operations rely on the timely availability of quality raw materials and
equipment, which could pose a risk if there are disruptions in the supply chain.
3. Capacity Constraints
Limited production capacity may hinder the company's ability to handle large-scale
projects or meet rapidly increasing customer demands.
3.8 Opportunities
1. Growing Construction Sector
2. Technological Advancements
3.9 Threats
1. Intense Competition
The foundry industry in Uganda is competitive, with both local and international players
vying for market share. Mawakato Technical Services may face pricing pressure and the
risk of losing customers to competitors.
2. Technological Disruption
1. Some of the work needed the use of heavy tools. In such cases, help was sought from
other people in the foundry to help.
2. Flooding at the metal melting section.
3. Rainfall disrupts the work especially when melting cast iron
4. Lack of well scheduled training program.
5. Lack of trust from the workers that I could actually do the mold and comes out
perfectly.
4.4 Recommendations
Following what transpired during the industrial training especially the challenges I
encountered, I recommend the following.
1. All the necessary tools in the workshop should be availed to enable each trainee take
part in the practical sessions and thus reducing the work backlogs.
2. A well-designed training program for trainees and an immediate person responsible
for their affairs.
3. More trained staff should be deployed to enable easy handling of large groups of
trainees.
4. Student-instructor relationship should be bridged and emphasized by the department
to enable students get more exposure.
5. More safety gadgets such as welding shields, grinding machines, cutting goggles
should be acquired especially for welding and fabrication.
4.5 Conclusion
My internship in the foundry has been a valuable and transformative experience that has left a
lasting impression on my professional journey. Over the course of 7 weeks, I had the
privilege of immersing myself in the world of metal casting and witnessing the intricacies of
the manufacturing process firsthand.
I learned to value precision and quality, recognizing their role in producing flawless castings.
Moreover, the collaborative nature of the foundry environment taught me the importance of
effective communication and teamwork. Engaging with the cross-functional teams and
contributing to real projects reinforced the significance of cooperation and coordination to
achieve successful outcomes.
Furthermore, witnessing the tangible results of my contribution in the form of cast parts
added a sense of fulfillment and purpose to my work. The satisfaction of seeing a product
evolve from a simple pattern to a final casting solidified my passion for the manufacturing
industry.
I am grateful to the entire team at Mawakato Technical Service Ltd for their guidance,
support, and willingness to share their expertise. Their mentorship was invaluable and greatly
contributed to the making my internship a truly enriching experience.