CASTING

PROCESSES
GROUP-1

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 CASTING
Casting is a method of manufacturing
where a liquid substance is poured into a
mold with a hollow space in the desired
shape. Once it hardens, the resulting
solid part, called a casting, is removed
from the mold.

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 The first castings can be dated
back to ancient China in the 4th
century B.C. Through the metal
casting process, molten metal is
poured into a mold that matches
the final dimensions of the
HISTORY AND EVOLUTION finished product.
OF CASTING During the Middle Ages, casting
techniques expanded across
Europe. The Renaissance saw
advancements in casting methods,
with bronze sculptures becoming
more complicated.

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 The Industrial Revolution
brought improvements in
materials and techniques, leading
to the mass production of cast
metal products.

HISTORY AND EVOLUTION

OF CASTING In the modern era, casting has
evolved significantly, incorporating
advanced technologies like computer
simulations and 3D printing for
creating molds. The process remains
crucial in various industries, including
manufacturing, automotive,
aerospace, and art
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 Today, castings are used in
virtually all walks of life. The
following is a partial list of
applications, with transport sector
and heavy equipment taking up
over 50% of castings produced:
HISTORY AND EVOLUTION
OF CASTING
Transport:
Automobile,
aerospace, railways
and shipping
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 Heavy equipment:
Construction,
farming and mining
HISTORY AND EVOLUTION
OF CASTING
Machine tools: Machining,
casting, plastic molding,
forging, extrusion and forming

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 Household:
Appliances, kitchen,
gardening equipment
and furniture
HISTORY AND EVOLUTION
OF CASTING
Art objects: Sculptures,
idols, furniture, lamp stands
and decorative items

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 TYPES OF CASTING
1. Sand Casting - Uses sand molds to
create complex metal parts, suitable
for large components and prototypes.

2. Gravity Die Casting - Involves 3. Pressure Die Casting -

pouring molten metal into a Utilizes high pressure to inject
reusable metal mold, offering molten metal into a mold,
better surface finish and ensuring precise shapes and
dimensional accuracy. fine details.

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 TYPES OF CASTING
4. Investment Casting - Also known as
"lost-wax casting," it produces intricate
and detailed parts, often used for
jewelry or aerospace components.

5. Plaster Casting - Uses a 6. Centrifugal Casting - Spins

mixture of plaster and water to the mold to force molten metal
create molds, commonly used into its shape, ideal for
for casting sculptures and art cylindrical objects like pipes
pieces. and tubes.

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 TYPES OF CASTING
7. Lost-Foam Casting - Exploits foam
patterns that evaporate upon contact
with molten metal, suitable for intricate
designs and one-piece construction.

8. Vacuum Casting - Removes 9. Squeezing Casting - Applies

air from the mold to improve pressure to the mold during
metal flow and reduce defects, solidification, resulting in
commonly used for high-quality denser and stronger castings.
and intricate parts.

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 TYPES OF CASTING
10. Continuous Casting - Produces long
strands of metal with a constant cross-
section, often used for producing metal
sheets, rods, and bars.

Although casting is one of the

11. Shell Molding - Involves
oldest known manufacturing
creating thin-shell molds using
techniques, modern advances in
resin-coated sand, offering good
casting technology have led to a
surface finish and dimensional
broad array of specialized
accuracy.
casting methods.
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 SAND CASTING GRAVITY DIE CASTING PRESSURE DIE CASTTING INVESTMENT CASTING

PLASTER CASTING CENTRIFUGAL CASTING LOST-FOAM CASTING VACUUM CASTING

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SQUEEZING CASTING CONTINUOUS CASTING SHELL MOLD CASTING

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GENERAL DESIGN CONSIDERATIONS
OF CASTING ARE AS FOLLOWS:
1. ·Always keep the stressed areas of the part in
compression.
2. ·Round all external corners.
3. ·Wherever possible section thickness throughout
should be held as uniform as compatible with
overall design considerations.
4. ·Avoid the concentration of metal at the junction.
5. ·Avoid very thin sections.
6. ·Short blast the parts wherever possible.

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 UNDERSTAND WHY METAL CASTING PROCESSES ARE
OFTEN SELECTED AMONG OTHER MANUFACTURING
PROCESSES.

It is a highly cost-effective way to

produce large quantities of parts quickly
and efficiently.

Relatively straightforward
Greater design flexibility.
and can be mastered
The lack of tooling.
with minimal training.

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 CREATE THE PATTERN
Before you make your
mold, you must create a
pattern to determine the
mold’s shape.
EXPLAIN THE DIFFERENT
PROCESSES INVOLVED IN MAKE THE MOLD
THE CASTING OF METALS. After you have created a
pattern, it is time to make
your mold.

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 CHOOSE THE METALLIC ALLOY
All metal castings are
produced from either
ferrous or non-ferrous
alloys.
EXPLAIN THE DIFFERENT
PROCESSES INVOLVED IN MELT THE ALLOY
THE CASTING OF METALS. Melting processes vary
between alloys because
each alloy will have a
different melting
temperature.
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 POUR INTO THE MOLD
Pour the molten metal into
the mold cavity.

EXPLAIN THE DIFFERENT

PROCESSES INVOLVED IN REMOVE THE CASTING FROM
THE CASTING OF METALS. THE MOLD
When the metal has
cooled and solidified, you
can remove it from the
mold.

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 FINISHING
File and polish your solid
metal cast! This may
involve cleaning your cast
metal object, like scrubbing
EXPLAIN THE DIFFERENT away excess mold material
PROCESSES INVOLVED IN in water, breaking off the
THE CASTING OF METALS. casting gates with clippers
for small objects, or even
an angle grinder for large
pieces.

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 CLASSIFICATION OF CASTING
PRACTICES OF METAL
Die casting involves forcing the molten metal
into the permanent cavity of steel mould,
called a die, under very high pressure of about
90 to 2000 times the atmospheric pressure.

The Centrifugal casting The Continuous Casting Process

process involves pouring of
molten metal into a rotating
mould cavity, caused by
centrifugal acceleration.
basically involves controlling the
flow of a stream of molten metal
that comes out from a water-cooled
mould or orifice in order to solidify
and form a continuous rod.
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CREATE A SAMPLE
PRODUCT USING
CASTING

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WHAT IS PLASTER
MOLD CASTING?
Plaster mold casting, also called
rubber plaster molding (RPM), is a
method of producing aluminum or zinc
castings by pouring liquid metal into
plaster (gypsum) molds.

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 STEP 1: MODEL OR MASTER PATTERN
1. Constructed from customer drawing or
CAD file.
2. Stereolithography, traditional hand
crafted or machined.
3. Model is engineered to include:
4. A) Metal shrinkage.
5. B) Mold taper (if required)
6. C) Machine stock (if required).
7. We can "clone" or adapt customer
supplied model if requested.

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 STEP 2: FOUNDRY PATTERN EQUIPMENT
1. Negative molds are made from model.
2. Core plugs are made from negative
molds.
3. A positive resin cope and drag pattern is
now made from the negative molds.
4. Core boxes are made from the core plugs
5. Gating, runner system and flasks are
added as necessary.
6. Duplicate sets of tooling can be made
from the master negative.

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 STEP 3: PLASTER MOLD
1. A liquid plaster slurry is poured around
the cope and drag pattern and into the
core boxes.
2. The plaster mold is next removed from
the cope and drag patterns.
3. The plaster mold and cores are then
baked to remove moisture.

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 STEP 4: POUR CASTING
1. Molten metal is prepared by degassing,
and a spectrographic sample is taken to
check the chemical analysis.
2. The molten metal is then poured into the
assembled plaster mold.
3. The plaster is removed by mechanical
knock-out and high pressure waterjet.
4. When the casting has cooled, the gates
and risers are then removed.

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 About

STEP 5: SECONDARY OPERATIONS

1. The raw castings are inspected and serialized.
2. Castings may then require (per customer
specifications):
A) Heat treatment
B) X-Ray
C) Penetrant inspection
3.After finish inspection, casting is ready for:
A) Machining
B) Chemical film, chromate conversion, paint
or special finishes
C) Assembly
D) Form-in-place gasketing.

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THANK YOU!

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