EXPENDABLE & PERMANENT

MOLD CASTING

UI-MST-I
 EXPENDABLE MOLD CASTING PERMANENT MOLD CASTING

• SHELL MOLD CASTING • PRESSURE DIE CASTING

• VACUUM MOLD CASTING
• VACUUM DIE CASTING
• CO2 CASTING
• INVESTMENT CASTING (LOST WAX) • SLUSH DIE CASTING
• EVAPORATIVE CASTING (LOST FOAM )
Special Metal Casting
• EXPENDABLE PLASTER MOLD (ANTIOCH
PROCESS) • Centrifugal Casting
• CERAMIC MOLD (SHAW PROCESS) • Continuous Casting
• Squeeze Casting
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• Chilled Metal Casting
 SHELL MOLD CASTING
• MOLD LIKE A SHELL - MADE BY THE MIXTURE OF SAND
AND THERMOSETTING RESIN BINDER. DEVELOPED IN
GERMANY DURING THE EARLY 1940S,
• THIS MOLD IS LIGHT WEIGHTED AND HAVE HIGH STRENGTH
WHICH MAKES IT SUITABLE FOR AUTOMATIC CASTING.
• THIS PROCESS IS SUITABLE FOR BOTH FERROUS AND NON-
FERROUS CASTING BUT IT IS MOSTLY USED FOR STEEL, CAST
IRON, CARBON STEEL, ALLOY STEEL, STAINLESS STEEL,
ALUMINUM ALLOYS, AND COPPER ALLOYS.
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 Process

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 ADVANTAGES:
• THIN AND COMPLEX SECTION CAN BE EASILY CAST.

• HIGH DIMENSION ACCURACY AND GOOD SURFACE FINISH.

• EASILY AUTOMATED.
• IT CAN BE OPERATE BY AN SEMI SKILLED OPERATOR.

• NO FURTHER MACHINING REQUIRED.

DISADVANTAGES:
• SPECIAL METAL PATTERN REQUIRED WHICH MAKES IT EXPENSIVE FOR LARGE CASTING.

• IT IS NOT SUITABLE FOR SMALL BATCH PRODUCTION.

• SHELL MOULDS ARE LESS PERMEABLE COMPARE TO GREEN SAND MOULD.
• SIZE AND WEIGHT LIMITATION.
APPLICATIONS:
• MOST OF INDUSTRIAL PRODUCTS LIKE GEAR BOX HOUSING, CONNECTING ROD, SMALL SIZE BOATS,
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TRUCK HOODS, CYLINDRICAL HEAD, CAMSHAFT, VALVE BODY ETC. ARE MADE BY SHELL MOULDING.
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 VACUUM MOLD CASTING
• VACUUM MOLD CASTING, ALSO KNOWN IN
MANUFACTURING INDUSTRY AS THE V PROCESS.
• EMPLOYS A SAND MOLD THAT CONTAINS NO MOISTURE
OR BINDERS.
• THE INTERNAL CAVITY OF THE MOLD HOLDS THE SHAPE OF
THE CASTING DUE TO FORCES EXERTED BY THE PRESSURE
OF A VACUUM.
• VACUUM MOLDING IS A CASTING PROCESS THAT WAS
DEVELOPED IN JAPAN AROUND 1970 6

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 V - Mold - Process

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 PROPERTIES AND CONSIDERATIONS OF MANUFACTURING BY VACUUM MOLD CASTING
• IN VACUUM MOLD CASTING MANUFACTURE THERE IS NO NEED FOR SPECIAL MOLDING SANDS
OR BINDERS.
• SAND RECOVERY AND RECONDITIONING, A COMMON PROBLEM IN METAL CASTING INDUSTRY,
IS VERY EASY DUE TO THE LACK OF BINDERS AND OTHER AGENTS IN THE SAND.
• WHEN MANUFACTURING PARTS BY VACUUM MOLD CASTING THE SAND MOLD CONTAINS NO
WATER, SO MOISTURE RELATED METAL CASTING DEFECTS ARE ELIMINATED.
• THE SIZE OF RISERS CAN BE SIGNIFICANTLY REDUCED FOR THIS METAL CASTING PROCESS,
MAKING IT MORE EFFICIENT IN THE USE OF MATERIAL.
• CASTING MANUFACTURE BY VACUUM MOLDING IS A RELATIVELY SLOW PROCESS.
• VACUUM MOLD CASTING IS NOT WELL SUITED TO AUTOMATION.

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 CO2 CASTING

• KIND OF SAND CASTING PROCESS.

• IN THIS PROCESS THE SAND MOLDING MIXTURE IS HARDENED BY BLOWING GAS OVER THE MOLD.
• THIS PROCESS IS FAVORED BY HOBBY METAL CASTERS BECAUSE A LOT OF COST CUTTING CAN BE
DONE.
• IN ADDITION, ONE CAN BE SURE OF GETTING DIMENSIONALLY ACCURATE CASTINGS WITH FINE
SURFACE FINISH. BUT, THIS PROCESS IS NOT ECONOMICAL THAN GREEN SAND CASTING PROCESS.

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 • FEATURES HIGH ACCURACY MOLDING SYSTEMS INCORPORATING THE GAS
CARBON DIOXIDE AS A CATALYST.
• ADVANTAGES PROVIDES GOOD DIMENSIONAL TOLERANCES THROUGH STRONG
CORE AND MOLD
• PROVIDES EXCELLENT CASTING SURFACE FINISHES
• GENERALLY USED FOR HIGH-PRODUCTION RUNS
• ACCOMMODATES A WIDE RANGE OF CORE AND MOLD SIZES.
• WHEN USED FOR MAKING CORES, THE CO2 PROCESS CAN BE AUTOMATED FOR
LONG DURATIONS & SPEEDY PRODUCTION RUNS.
• APPLICATIONS IDEAL FOR CASTING APPLICATIONS WHERE SPEED AND FLEXIBILITY
IS PARAMOUNT.
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 INVESTMENT CASTING
• MANUFACTURING PROCESS IN WHICH A WAX PATTERN IS COATED WITH A
REFRACTORY CERAMIC MATERIAL. ONCE THE CERAMIC MATERIAL IS HARDENED ITS
INTERNAL GEOMETRY TAKES THE SHAPE OF THE CASTING. THE WAX IS MELTED OUT
AND MOLTEN METAL IS POURED INTO THE CAVITY WHERE THE WAX PATTERN WAS.
THE METAL SOLIDIFIES WITHIN THE CERAMIC MOLD AND THEN THE METAL CASTING
IS BROKEN OUT. THIS MANUFACTURING TECHNIQUE IS ALSO KNOWN AS THE LOST
WAX PROCESS.
• INVESTMENT CASTING WAS DEVELOPED OVER 5500 YEARS AGO AND CAN TRACE
ITS ROOTS BACK TO BOTH ANCIENT EGYPT AND CHINA.
• PARTS MANUFACTURED IN INDUSTRY BY THIS PROCESS INCLUDE DENTAL FIXTURES,
GEARS, CAMS, RATCHETS, JEWELRY, TURBINE BLADES, MACHINERY COMPONENTS
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AND OTHER PARTS OF COMPLEX GEOMETRY.
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 EVAPORATIVE /EXPANDED POLYSTYRENE CASTING
CONSUMABLE OR EVA-FOAM CASTING IS A SAND CASTING PROCESS WHERE
THE FOAM PATTERN EVAPORATES INTO THE SAND MOLD. A PROCESS SIMILAR TO
INVESTMENT CASTING, THIS EXPENDABLE CASTING PROCESS IS PREDICTED TO
BE USED FOR 29% OF ALUMINUM AND 14% OF FERROUS CASTING IN 2010.
THERE ARE TWO MAIN EVAPORATIVE CASTING PROCESS LOST-FOAM CASTING
AND FULL MOLD CASTING WHICH ARE WIDELY USED BECAUSE INTRICATE
DESIGN CAN BE CAST WITH RELATIVE EASE AND WITH REASONABLE EXPENSE.
THE MAIN DIFFERENCE BETWEEN THE TWO IS THAT IN THE LOST-FOAM CASTING
UNBONDED SAND IS USED AND IN THE FULL-MOLD CASTING GREEN SAND OR
BONDED SAND IS USED.
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 Eva – Foam Process

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• APPLICATIONS: EVAPORATIVE CASTINGS IS USED FOR STEEL-CASTING CAST IRON PARTS LIKE
WATER PIPE AND PUMP PARTS, ALUMINUM CASTINGS ETC..
PARTS PRODUCED IN MANUFACTURING INDUSTRY USING THIS PROCESS INCLUDE
CRANKSHAFTS, CYLINDER HEADS, MACHINE BASES, MANIFOLDS, AND ENGINE BLOCKS.

ADVANTAGES:
• HIGH DIMENSIONAL ACCURACY AND SUPERIOR CASTING SURFACE SMOOTHNESS
• REDUCED WORK PROCESS UNLIKE OTHER CASTING METHODS
• LIGHT WEIGHT CASTING ARE BE DONE
• CASTING HAVE IMPROVED HEAT RESISTANCE AND ALSO ABRASION RESISTANCE AND OTHER
CAST STEEL PROPERTIES
• COMPLICATED SHAPES CAN BE CAST WITHOUT USING CORES OR DRAFTS.
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 PLASTER MOLD CASTING
• PLASTER CASTING IS SIMILAR TO SAND CASTING EXCEPT THAT PLASTER OF
PARIS (GYPSUM, CaSO4–2H2O)IS SUBSTITUTED FOR SAND AS A MOLD MATERIAL.
GENERALLY, THE FORM TAKES LESS THAN A WEEK TO PREPARE, AFTER WHICH A
PRODUCTION RATE OF 1–10 UNITS/HR-MOLD IS ACHIEVED, WITH ITEMS AS
MASSIVE AS 45 KG (99 LB) AND AS SMALL AS 30 G (1 OZ) WITH VERY GOOD
SURFACE FINISH AND CLOSE TOLERANCES.
• PLASTER CASTING IS AN INEXPENSIVE ALTERNATIVE TO OTHER MOLDING
PROCESSES FOR COMPLEX PARTS DUE TO THE LOW COST OF THE PLASTER AND
ITS ABILITY TO PRODUCE NEAR NET SHAPE CASTINGS.
• THE BIGGEST DISADVANTAGE IS THAT IT CAN ONLY BE USED WITH LOW MELTING
POINT NON-FERROUS MATERIALS, SUCH AS ALUMINIUM, COPPER, MAGNESIUM,
AND ZINC. 18

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 • ADVANTAGES OF PLASTER MOLD CASTING PROCESS
• CAN PRODUCE COMPLEX SHAPES.
• THIN SECTION CASTING.
• EXACT COPYING OF PATTERN DETAIL.
• DIMENSIONALLY ACCURATE CASTINGS.
• GOOD SURFACE FINISH.
• MINIMUM RESIDUAL STRESSES AND DISTORTION IN CASTINGS.

LIMITATIONS
• POOR PRODUCTIVITY AS IT HAS LENGTHY PROCESSING PROBLEMS.
• CLOSE MONITORING OF THE PRODUCTION PROCESS.
• THE PROBLEMS OF POOR MOLD PERMEABILITY.
• IMPAIRED MECHANICAL PROPERTIES A POSSIBILITY AS A RESULT OF SLOW
COOLING OF THE CASTING
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 ANTIOCH PROCESS
• USING ABOUT 50% SAND MIXED WITH THE PLASTER,
• HEATING THE MOLD IN AN AUTOCLAVE (AN OVEN THAT
USES SUPERHEATED STEAM UNDER PRESSURE), AND THEN
DRYING.
• THE RESULTING MOLD HAS CONSIDERABLY GREATER
PERMEABILITY THAN A CONVENTIONAL PLASTER MOLD.

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 APPLICATION:
IN INDUSTRY PARTS SUCH AS VALVES, TOOLING,
GEARS, AND LOCK COMPONENTS MAY BE
MANUFACTURED BY PLASTER MOLD CASTING.

ADVANTAGES:
• MORE UNIFORM GRAIN STRUCTURE IS CREATED
• MORE INTRICATE DESIGNS CAN BE MADE.

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PRESSURE DIE CASTING
PRESSURE DIE CASTING IS A QUICK, RELIABLE AND COST-
EFFECTIVE MANUFACTURING PROCESS FOR PRODUCTION OF
HIGH VOLUME, METAL COMPONENTS THAT ARE NET-SHAPED
HAVE TIGHT TOLERANCES.
BASICALLY, THE PRESSURE DIE CASTING PROCESS CONSISTS
OF INJECTING UNDER HIGH PRESSURE A MOLTEN METAL
ALLOY INTO A STEEL MOLD (OR TOOL). THIS GETS SOLIDIFIED
RAPIDLY (FROM MILLISECONDS TO A FEW SECONDS) TO
FORM A NET SHAPED COMPONENT. IT IS THEN
AUTOMATICALLY EXTRACTED.
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 ADVANTAGES OF PRESSURE DIE CASTING :
• LOWER COSTS COMPARED TO OTHER PROCESSES.
• ECONOMICAL - TYPICALLY PRODUCTION OF ANY NUMBER
OF COMPONENTS FROM THOUSANDS TO MILLIONS
BEFORE REQUIRING REPLACEMENT IS POSSIBLE.
• CASTINGS WITH CLOSE DIMENSIONAL CONTROL AND
GOOD SURFACE FINISH
• CASTINGS WITH THIN WALLS, AND THEREFORE ARE
LIGHTER IN WEIGHT
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 APPLICATION OF PRESSURE DIE CASTING
• AUTOMOTIVE PARTS LIKE WHEELS, BLOCKS, CYLINDER HEADS,
MANIFOLDS ETC.
• AEROSPACE CASTINGS.
• ELECTRIC MOTOR HOUSINGS.
• KITCHEN WARE SUCH AS PRESSURE COOKER.
• CABINETS FOR THE ELECTRONICS INDUSTRY.
• GENERAL HARDWARE APPLIANCES, PUMP PARTS, PLUMBING
PARTS
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 Hot Chamber Die Casting

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Centrifugal Casting
TYPES OF CENTRIFUGAL CASTING
•TRUE CENTRIFUGAL CASTING
PROCESS
• HORIZONTAL TRUE CENTRIFUGAL
CASTING
• VERTICAL TRUE CENTRIFUGAL CASTING
•SEMI CENTRIFUGAL CASTING PROCESS
•CENTRIFUGING PROCESS
• HORIZONTAL AXIS MACHINES ARE PREFERRED FOR LONG, THIN CYLINDERS,
• VERTICAL MACHINES FOR RINGS AND BEARINGS
 SEMI CENTRIFUGAL CASTING
• SEMI CENTRIFUGAL CASTING MANUFACTURE IS A
VARIATION OF THE TRUE CENTRIFUGAL PROCESS
• MAIN DIFFERENCE IS THAT IN SEMI CENTRIFUGAL
CASTING THE MOULD IS FILLED COMPLETELY
WITH MOLTEN METAL, WHICH IS SUPPLIED TO THE
CASTING THROUGH CENTRAL SPRUE
• THE FORCES GENERATED BY THE ROTATION OF THE
MOULD ENSURE THE DISTRIBUTION OF MOLTEN
MATERIAL TO ALL REGIONS OF THE CASTING
Semi centrifugal Casting
 CENTRIFUGE CASTING
PRINCIPLE
• IN CENTRIFUGE CASTING MANUFACTURE, MOULDS
EMPLOYED TO PRODUCE THE DESIRED CASTINGS ARE
ARRANGED AROUND A CENTRAL SPRUE
• THESE MOULD CONTAINS ALL THE NECESSARY GEOMETRY
FOR THE CAST PART, AS WELL AS THE GATING SYSTEM.
RUNNERS TRAVEL FROM THE CENTRAL SPRUE TO THE
MOULD ENTRANCES
• THIS PROVIDES A MEANS OF INCREASING THE FILLING
PRESSURE WITHIN EACH MOULD AND ALLOWS FOR
REPRODUCTION OF INTRICATE DETAILS
 ADVANTAGES:

• IT PROVIDES DENSE METAL AND HIGH MECHANICAL PROPERTIES.

• UNIDIRECTIONAL SOLIDIFICATION CAN OBTAIN UP TO A CERTAIN THICKNESS.

• IT CAN USE FOR MASS PRODUCTION.

• NO CORES ARE REQUIRED FOR CAST HOLLOW SHAPES LIKE TUBES ETC.

• GATING SYSTEM AND RUNNER ARE TOTALLY ELIMINATED.

• ALL THE IMPURITY LIKE OXIDE OR OTHER SLAG PARTICLES, SEGREGATED AT CENTER FROM WHERE IT CAN EASILY REMOVE.

• IT REQUIRED LOWER POURING TEMPERATURE THUS SAVE ENERGY.

• LOWER CASTING DEFECTS DUE TO UNIFORM SOLIDIFICATION.

DISADVANTAGES:

• LIMITED DESIGN CAN BE CAST. IT CAN CAST ONLY SYMMETRICAL SHAPES.

• HIGH EQUIPMENT OR SETUP COST.

• IT IS NOT SUITABLE FOR EVERY METAL.

• HIGHER MAINTENANCE REQUIRED.

• HIGH SKILL OPERATOR REQUIRED.

• IN THIS CASTING PROCESS, SOLIDIFICATION TIME AND TEMPERATURE DISTRIBUTION IS DIFFICULT TO DETERMINE 38

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 Application:
It is widely used in aircraft industries to cast rings, flanges
and compressor casting.
It is used for cast Steam turbine bearing shell.
Roller for steel rolling mill is another example of centrifugal
casting.
It is used in automobile industries to cast gear blank,
cylindrical liners, piston rings etc.
It is used to cast bearings.
This process used to cast switch gear components used in
electronic industries.
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 CONTINUOUS CASTING

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 SQUEEZE CASTING
• LIQUID METAL FORGING, IS A COMBINATION OF CASTING AND FORGING
PROCESS.
• THE MOLTEN METAL IS POURED INTO THE BOTTOM HALF OF THE PRE-HEATED
DIE. AS THE METAL STARTS SOLIDIFYING, THE UPPER HALF CLOSES THE DIE
AND APPLIES PRESSURE DURING THE SOLIDIFICATION PROCESS.
• THE AMOUNT OF PRESSURE THUS APPLIED IS SIGNIFICANTLY LESS THAN USED
IN FORGING, AND PARTS OF GREAT DETAIL CAN BE PRODUCED. CORING
CAN BE USED WITH THIS PROCESS TO FORM HOLES AND RECESSES. THE
POROSITY IS LOW AND THE MECHANICAL PROPERTIES ARE IMPROVED.
• BOTH FERROUS AND NON-FERROUS MATERIALS CAN BE PRODUCED USING
THIS METHOD.
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 SQUEEZE CASTING

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 MELTING
FURNACES
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COMMON FURNACES IN FOUNDRY PRACTICE
• CUPOLAS
• DIRECT FUEL-FIRED FURNACES
• CRUCIBLE FURNACES
• ELECTRIC-ARC FURNACES
• INDUCTION FURNACES
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Cupola
Cast iron

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 DIRECT FUEL-FIRED FURNACES
• A SMALL OPEN-HEARTH, IN WHICH THE METAL CHARGE IS HEATED
BY FUEL BURNERS LOCATED ON THE SIDE OF THE FURNACE.
• THE ROOF OF THE FURNACE ASSISTS THE HEATING ACTION BY
REFLECTING THE FLAME DOWN AGAINST THE CHARGE.
• TYPICAL FUEL IS NATURAL GAS, AND THE COMBUSTION PRODUCTS
EXIT THE FURNACE THROUGH A STACK.
• AT THE BOTTOM OF THE HEARTH IS A TAP HOLE TO RELEASE THE
MOLTEN METAL.
• DIRECT FUEL FIRED FURNACES ARE GENERALLY USED IN CASTING
FOR MELTING NONFERROUS METALS SUCH AS COPPER BASE
ALLOYS AND ALUMINUM
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 CRUCIBLE FURNACES
• MELT THE METAL WITHOUT DIRECT CONTACT WITH A BURNING FUEL MIXTURE.
• THEY ARE SOMETIMES CALLED INDIRECT FUEL-FIRED FURNACES.
• CRUCIBLE FURNACES ARE USED FOR NONFERROUS METALS SUCH AS BRONZE, BRASS, AND ALLOYS OF ZINC AND
ALUMINUM.
• THREE TYPES OF CRUCIBLE FURNACES ARE USED IN FOUNDRIES: (A) LIFT-OUT TYPE, (B) STATIONARY, AND (C) TILTING
• THEY ALL UTILIZE A CONTAINER (THE CRUCIBLE) MADE OUT OF A SUITABLE REFRACTORY MATERIAL (E.G., A CLAY–
GRAPHITE MIXTURE) OR HIGH-TEMPERATURE STEEL ALLOY TO HOLD THE CHARGE.
• IN THE LIFT-OUT CRUCIBLE FURNACE, THE CRUCIBLE IS PLACED IN A FURNACE AND HEATED SUFFICIENTLY TO MELT THE
METAL CHARGE. OIL, GAS, OR POWDERED COAL ARE TYPICAL FUELS FOR THESE FURNACES. WHEN THE METAL IS MELTED,
THE CRUCIBLE IS LIFTED OUT OF THE FURNACE AND USED AS A POURING LADLE.
• THE OTHER TWO TYPES, SOMETIMES REFERRED TO AS POT FURNACES, HAVE THE HEATING FURNACE AND CONTAINER AS
ONE INTEGRAL UNIT.
• IN THE STATIONARY POT FURNACE, THE FURNACE IS STATIONARY AND THE MOLTEN METAL IS LADLED OUT OF THE
CONTAINER.
• IN THE TILTING POT FURNACE, THE ENTIRE ASSEMBLY CAN BE TILTED FOR POURING. 47

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CRUCIBLE FURNACES

(a) lift-out crucible, (b) stationary pot, and (c) tilting-pot furnace
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ELECTRIC-ARC FURNACES
• IN THIS FURNACE TYPE, THE CHARGE IS MELTED BY HEAT GENERATED FROM AN ELECTRIC ARC.
VARIOUS CONFIGURATIONS ARE AVAILABLE, WITH TWO OR THREE ELECTRODES
• POWER CONSUMPTION IS HIGH, BUT ELECTRIC-ARC FURNACES CAN BE DESIGNED FOR HIGH
MELTING CAPACITY (23,000–45,000 KG/HR OR 25–50 TONS/HR), AND THEY ARE USED
PRIMARILY FOR CASTING STEEL.

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 INDUCTION FURNACES
• USES ALTERNATING CURRENT PASSING THROUGH A COIL
TO DEVELOP A MAGNETIC FIELD IN THE METAL, AND THE
RESULTING INDUCED CURRENT CAUSES RAPID HEATING AND
MELTING OF THE METAL.
• THE ELECTROMAGNETIC FORCE FIELD CAUSES A MIXING
ACTION TO OCCUR IN THE LIQUID METAL. ALSO, SINCE THE
METAL DOES NOT COME IN DIRECT CONTACT WITH THE
HEATING ELEMENTS, THE ENVIRONMENT IN WHICH MELTING
TAKES PLACE CAN BE CLOSELY CONTROLLED. ALL OF THIS
RESULTS IN MOLTEN METALS OF HIGH QUALITY AND PURITY,
AND INDUCTION FURNACES ARE USED FOR NEARLY ANY
CASTING ALLOY WHEN THESE REQUIREMENTS ARE
IMPORTANT.
• MELTING STEEL, CAST IRON, AND ALUMINUM ALLOYS ARE
COMMON APPLICATIONS IN FOUNDRY WORK. 50

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