CASTING

GROUP5

MEMBERS:

ARBOLADO | BAYOTLANG
DAGDAG | LAGUARDIA
LAQUIHON | LLENDAO
NUÑEZ | VICTORE
Casting is a manufacturing process in
which molten material, like metal, is
poured into a mold and allowed to
harden. Once solidified, the mold is
broken or ejected to retrieve the
casting. This method enables the
production of intricate and complex
components with specific properties.
MARKET TREND
MARKET TREND
TYPES OF CASTING
 SAND CASTING
Sand casting is a versatile casting process that can be used to cast any
metal alloy, ferrous or non-ferrous. It is widely used for mass production
in industrial units, such as automotive metal casting parts, like engine
blocks, cylinder heads, crankshafts, etc.
GRAVITY DIE CASTING

Gravity die casting, also typically

known as permanent mold casting,
uses reusable molds made of
metal, like steel, graphite etc. to
fabricate metal and metal alloys.
This type of metal casting can
manufacture various parts like
gears, gear housing, pipe fittings,
wheels, engine pistons, etc.
PRESSURE DIE CASTING
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.
PRESSURE DIE CASTING
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.
 INVESTMENT CASTING
Investment casting, also known as lost-wax casting, is a process that invests wax
pattern with refractory material and a binding agent to shape a disposable
ceramic mold, and then molten metal is poured into the mold to make metal
castings. Investment casting is an expensive and labor-intensive process and can
be used for mass production or in complex castings to produce metal casting
products ranging from gears, bicycle trunks, moto discs, and spare parts in
blasting machines.
PLASTER CASTING
The plaster casting process is similar
to sand casting, except that the
mold is made of a mixture called
‘Plaster of Paris’. Due to the low
thermal conductivity and heat
capacity of plaster, it cools the
metal more slowly as compared to
sand, which helps in attaining high
accuracy, especially for thin cross-
section parts. However, it is not
suitable for high-temperature
ferrous materials.
 CENTRIFUGAL CASTING
Centrifugal casting, also known as roto casting, is a process for industrially
manufacturing cylindrical parts with centrifugal forces. This type of metal casting
uses a preheated spinning die in which the molten metal is poured. The
centrifugal forces help to distribute the molten metal within the die at high
pressure.
LOST-FOAM CASTING
Lost-foam casting method is
similar to investment casting with
the difference that it uses foam
for the pattern instead of wax.
Once the pattern is formed,
coating with a refractory ceramic
takes place by dipping, coating,
spraying, or brushing. Then, the
molten metal is poured into the
mold to form the desired product.
VACUUM CASTING
Vacuum casting, as the name suggests,
is the type of casting where production
occurs under vacuum pressure of 100
bar or less to exhaust gas from the
mold cavity. In this process, molten
metal is poured into the mold cavity
inside a vacuum chamber in order to
eliminate bubbles and air pockets. The
vacuum evacuation of the die cavity
reduces the entrapment of gases
within the cavity during the metal
injection process. Finally, the metal is
cured in a heating chamber and
removed from the mold.
 SQUEEZING CASTING
Liquid forging or squeeze casting is a hybrid metal forming process that merges
permanent mold casting and die forging in a single step. In this process, a
specific amount of molten metal alloy is injected into a die, and pressure is
applied to shape it. Then, the metal part is heated over melting temperature
and extracted from the die.
CONTINUOUS CASTING

As the name suggests, it allows

consistent mass production of
metal profiles with a constant
cross-section. This type of casting
is popular in the production of
steel bars. Also, the vertical cast
creates semi-continuous casting
like billets, ingots, bars, etc.
SHELL MOLDING
Shell molding is an expendable
mold casting process. It is similar
to the sand casting process
except for that the hardened
shell of sand forms the mold
cavity instead of a flask of sand.
The sand used is finer than that
utilized in sand casting and it is
mixed with a resin so that it can
be heat treated and hardened
into the shell around the
pattern.
Molds and patterns are important equipment and
components in many sectors, particularly in
manufacturing and casting. Their significance lies
on their capacity to produce precise and
consistent shapes, which is essential for making
high-quality and accurate goods. Molds and
patterns are critical components of modern
manufacturing and production processes. They
improve efficiency, precision, and cost-
effectiveness, making them crucial tools in a
variety of sectors that require high-quality,
reproducible products.
TYPES OF molding
 INJECTION MOLDING
Injection molding is a manufacturing method that involves injecting
molten plastic material into a mold cavity to make a variety of plastic
parts and products. It is an extremely versatile and efficient way of mass-
producing plastic components. Injection molding is used to make things
such as automobile components, consumer goods, medical devices,
packaging, toys, and many more.
 DIE CASTING
Die casting is a common manufacturing process for generating
complicated and precise metal parts. It entails pouring molten metal
under high pressure into a mold or die and then allowing it to harden,
producing a final product with outstanding dimensional precision, surface
quality, and strength.
 BlOW MOLDING
Blow molding is a manufacturing process that is generally used to produce
hollow plastic objects such as bottles, containers, and various other
consumer and industrial products. Its capacity to efficiently generate
hollow plastic parts while remaining cost-effective and design versatile
makes it a useful manufacturing technology.
 Compression Molding
Compression molding is a type of manufacturing that is commonly used to
manufacture molded components or products, but it is not a type of
casting. Compression molding, on the other hand, is a method of shaping
and forming materials, often thermosetting polymers or rubber, with heat
and pressure.
 Thermoforming
Thermoforming is a unique industrial technique used to shape
thermoplastic materials and is not connected to casting. Thermoforming is
the process of heating a thermoplastic sheet until it becomes malleable
and then shaping it into a precise shape with the help of a mold or tool.
Unlike casting, which uses liquid materials and molds, thermoforming
works with solid sheets of thermoplastic materials.
TYPES OF Patterns
SINGLE PIECE PATTERN

also known as SOLID

PATTERN.
most affordable.
ideal for simple processes
and small-scale
production.
TWO PIECE PATTERN

also known as SPLIT PIECE

PATTERN.
popular for intricate
casting.
made of two parts: the
drag part and the cope
part where the dowel pins
lie.
MULTI-PIECE PATTERN

good for difficult-to-make

complex designs.
consists of three or more
patterns that aid in mould
making.
in a three-piece pattern; the
top part is called cope, drag for
the bottom part and the
middle part is the check box.
MATCH PLATE PATTERN

made in two halves and

mounted on opposite sides
of a wood or metal match
plate.
commonly used in metal
casting, such as aluminum.
typically has a high yield,
precise casting and a high
cost.
GATE PATTERN

also known as GATED

PATTERN.
utilized to manufacture
several pieces within a single
mold.
created by linking some
patterns and gates, providing
a common runner for the
molten metal.
SWEEP PATTERN

shapes the cavity by rotating a

wooden board along one edge.
has three parts; spindle, base and
sweep, which is a.k.a. a wooden
board.
creates cavity in the vertical
direction, and the base is attached
with sand.
produces a casting in a remarkably
short period.
SKELETON PATTERN

large in size and a good

choice for castings with
simple size and shape.
costly and unadaptable
but very effective at
removing extra sand.
widely used in pit or floor
welding industries.
LOOSE PIECE PATTERN

assists in removing one

piece of the solid pattern
that is above or below the
mould’s parting plane.
expensive as it requires
additional skilled labour.
used in the production of
axle pins.
COPE AND DRAG PATTERN

the cope and drag parts are

prepared separately as the
entire mould is too heavy for
one operator to handle.
the cavity created is similar to
that of two-piece pattern but
this is used in large-scale
casting like flange pipe
manufacturing.
SHELL PATTERN

excellent choice for

creating hollow-shaped
structures.
divided down the middle
parts, where the outer
shapes serve as the mould
while the inside shapes
serve as the core.
FOLLOW BOARD PATTERN

uses a simple wooden

board that serves as the
base in this pattern.
applied in operations
where the casting
structures are brittle and
might fracture when
pressure is applied.
SEGMENTAL PATTERN

commonly used for circular

castings.
moves under the control of a
central pivot. proceeds to the
next section after ramming
the previous one. the whole
rotational motion is repeated
to finish the mould.
ADVATANGES
Any simple and complex shape can be produced or form
Practically any kind of material can be casted
It does not have any directional properties
It is possible that any size can be produced up to 200 tons
Often the CHEAPEST and MOST DIRECT way of producing a shape with certain desired
mechanical properties
There are certain metals and alloys for gas turbines that cannot be worked
mechanically and can only be casted
heavy equipments can be thrown easily in the required size rather than fabricating
them by joining several small pieces
BEST SUITED for composite components requiring different properties in various
direction
 LIMITATIONS:
Defects are unavoidable
It has poor surface finish.
Relatively poor dimensional consistency and accuracy
A high tooling cost and a long set-up time.
Poor working environment with high temperature, dust, and high labor intensity.
Casting: Definition, Importance, Types,
REFERENCES
and How It Works. (n.d.). Www.xometry.com.
https://www.xometry.com/resources/casting/what-is-casting/

ClubTechnical, & ClubTechnical. (2021, December 9). What is Casting? Advantages, Limitations, Defects, Types. ClubTechnical.
https://clubtechnical.com/casting?fbclid=IwAR3PPI80PvnHVAt_Om8B9yeNQJyQ-6-KybUIrN-GepboYT21oK__S-uCuZ0

Marzeyeh. (2022, May 9). Top 6 Advantages of metal castings for Manufacturing. PreciseCast 2023.
https://precisecast.com/advantages-of-metal-castings/?
fbclid=IwAR2bYsclsbtCSu5wsK2EwX10r8kQzcS0B672vAeBRkzbm4dIrZLzVjx0YsE

Leo. (2022, March 7). The advantages and disadvantages of sand casting. Auminium Die Casting Company.
https://oeform.com/the-advantages-and-disadvantages-of-sand-casting/

Rapiddirect. (2022, August 12). 11 Different Types of Casting Process - rapiddirect. Rapiddirect.
https://www.rapiddirect.com/blog/different-types-of-casting-process/

Metal casting market: Global industry analysis and forecast (2023-2029). (2023, October 3). MAXIMIZE MARKET RESEARCH.
https://www.maximizemarketresearch.com/market-report/metal-casting-market/1613/
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GROUP5