THE UNIVERSITY OF BAMENDA

NATIONAL HIGHER
MECHANICAL AND
POLYTECHNIC
INDUSTRIAL
INSTITUTE
ENGINEERING

MECHANICAL AND INDUSTRIAL ENGINEERING

ADVANCE CASTING AND WELDING

.
GROUP 2( RECENT TRENDS IN CASTING AND FOUNDRY )
CODE: MECE6103
Course instructor: Engr BECHING ROLAND ORU

PRESENTED BY

BEMSI RANDOLPH CHIA UBa23EP341

CARLSON CHIA UBa23EP342
CHIANKEM LAURENTINE
CHIAFIE UBa23EP343
DABA EDYCLIFF FOGWE UBa23EP344
FONGOH FUNWI DIVINE UBa23EP345
JOHN-BAPTIST DOBGIMA
NTALI UBa23EP346
KONGNSO FRANKLINE
TANAYEN UBa23EP348
MBAH MERCY NAAH UBa23EP345

MBIADA NYONKEU FAUSTIN UBa20EP0467

DECEMBER 2023
Contents
1
RECENT TRENDS IN CASTING AND FOUNDRY LAYOUT..............................................1
1.1 SHELL MOULDING............................................................................................ 1
Pattern creation........................................................................................................... 2
Mold creation..............................................................................................................2
Mold assembly............................................................................................................ 2
Pouring.......................................................................................................................2
Cooling.......................................................................................................................3
Casting removal.......................................................................................................... 3
1.2 PRECISION INVESTMENT CASTING...............................................................3
Making of pattern............................................................................................................3
Making of mould.............................................................................................................3
Removal of pattern from mould (Burnout).........................................................................4
Preparing of mould and casting (Preheating, Pouring).........................................................4
Applications................................................................................................................... 4
Advantages................................................................................................................. 4
Disadvantages............................................................................................................. 5
1.3 CO2 MOULDING................................................................................................ 5
Applications................................................................................................................... 6
Advantages.....................................................................................................................6
Disadvantages.................................................................................................................6
1.4 Centrifugal casting..............................................................................................7
1.5 Die casting.........................................................................................................11
1.6 Continuous casting........................................................................................... 14
Range of continuously cast sections.............................................................................15
1.7 Counter gravity low pressure casting process..................................................16
Sequencing casting.................................................................................................... 17
Semisolid processes...................................................................................................17
1.8 Layout of mechanized foundry..........................................................................17
1.9 Material handling in foundry pollution control in foundry...................................19
1.10. Computer aided design in casting process........................................................21
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List of figures
Figure 1: shell moulding process......................................................................................2
Figure 2: CO2 molding process........................................................................................5
Figure 3: centrifugal casting.............................................................................................8
Figure 4: die casting....................................................................................................... 11
Figure 5: hot chamber die casting..................................................................................12
Figure 6: cold chamber die casting................................................................................12
Figure 7: Counter gravity low pressure casting process.................................................17
RECENT TRENDS IN CASTING AND FOUNDRY LAYOUT

1.1 SHELL MOULDING

Shell molding, also known as shell-mold casting, is an expendable mold casting process that
uses resin covered sand to form the mold. As compared to sand casting, this process has better
dimensional accuracy, a higher productivity rate, and lower labour requirements. It is used for
small to medium parts that require high precision.

Shell molding was developed as a manufacturing process during the mid-20th century in
Germany. It was invented by German engineer Johannes Crooning. Shell mold casting is a metal
casting process similar to sand casting, in that molten metal is poured into an expendable mold.

However, in shell mold casting, the mold is a thin-walled shell created from applying a sand-
resin mixture around a pattern. The pattern, a metal piece in the shape of the desired part, is
reused to form multiple shell molds.

A reusable pattern allows for higher production rates, while the disposable molds enable complex
geometries to be cast. Shell mold casting requires the use of a metal pattern, oven, sand-resin
mixture, dump box, and molten metal.

Shell mold casting allows the use of both ferrous and non-ferrous metals, most commonly using
cast iron, carbon steel, alloy steel, stainless steel, aluminum alloys, and copper alloys. Typical
parts are small-to-medium in size and require high accuracy, such as gear housings, cylinder
heads, connecting rods, and lever arms.

The shell mold casting process consists of the following steps:

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Figure 1: shell moulding process

Pattern creation

A two-piece metal pattern is created in the shape of the desired part, typically from iron or steel.
Other materials are sometimes used, such as aluminum for low volume production or graphite for
casting reactive materials.

Mold creation

First, each pattern half is heated to 175-370 °C (350-700 °F) and coated with a lubricant to
facilitate removal. Next, the heated pattern is clamped to a dump box, which contains a mixture
of sand and a resin binder. The dump box is inverted, allowing this sand-resin mixture to coat the
pattern. The heated pattern partially cures the mixture, which now forms a shell around the
pattern. Each pattern half and surrounding shell is cured to completion in an oven and then the
shell is ejected from the pattern.

Mold assembly

The two shell halves are joined together and securely clamped to form the complete shell mold.
If any cores are required, they are inserted prior to closing the mold. The shell mold is then
placed into a flask and supported by a backing material.

Pouring

The mold is securely clamped together while the molten metal is poured from a ladle into the
gating system and fills the mold cavity.
Cooling

After the mold has been filled, the molten metal is allowed to cool and solidify into the shape of
the final casting.

Casting removal

After the molten metal has cooled, the mold can be broken and the casting removed. Trimming
and cleaning processes are required to remove any excess metal from the feed system and any
sand from the mold.

1.2 PRECISION INVESTMENT CASTING

Precision investment casting, also known as the lost wax casting process, is an ancient metal
forming technology. The technique is several thousand years old, originally producing ornaments
and jewelry. Today, many high tech components are fabricated to tight tolerances using this
technology.

In this type of casting, mould is prepared around an expandable pattern, and a single gating
system is used to make a large number of casting. The pattern used to make mold is get
destroyed or it completely lost its shape during investment casting. The common pattern material
for precision investment casting wax, so this process is also known as lost-wax casting. The
other important pattern materials used in investment casting are plastic, wood, and mercury.
When mercury is used to make a pattern then the process is known as mercast.
Making of pattern

The first phase of investment casting is the preparation of pattern. The individual pattern is made
for each and every casting is to be made. The pattern material is wax; molten wax is injected
under high pressure into the metallic die. The wax is then allowed to solidify to produce the
pattern. This pattern is then ejected from die, and attached to the gating system.

Making of mould

The cluster of patterns attached to the gating system is then dipped into a slurry, made of
refractory /ceramic coating material. The excess slurry is allowed to drain off from the pattern. A
coating of material will formed as slurry drying. A thin shell is formed around the pattern. After

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curing of shell, the pattern is again dipped into slurry. The process repeats to increase the
thickness of shell gradually. The required shell thickness depends on the size and shape of
casting and properties of ceramic material used.

Removal of pattern from mould (Burnout)

The next step is the removal of pattern from the casting. It can be achieved by heating of mould.
The wax pattern is meltdown, and it is completely drained through sprue by inverting the mould.
The hot vapor of solvent such as trichloroethylene is used to remove remaining waxy residue in
the mould cavity. The wax that flows down can be reused to make another pattern.

Preparing of mould and casting (Preheating, Pouring)

The mould is then preheated certain temperature (depends on the complexity of casting and
material of casting and moulding). This reduces the last trace of wax and ensures proper filling
of thin sections of mold, which is very difficult to achieve in cold mould. The molten metal is
then poured into the mould cavity, sometimes slight pressure is preferable. After solidification,
the casting takes out of the ceramic shell by breaking it or chemically dissolving it.

Applications

This method of casting is used where high precision is required. It cannot use to make heavy
casting. Investment casting largely relied on making of very intrinsic shape that cannot cast by
another method. The common application includes jewelry, surgical equipment, vanes and blades
for gas turbine, bolts and triggers for firearms, impeller, and stainless steel valve bodies.
Advantages

 It is used for casting of complex shape that cannot be produced by any other method. No
limit of geometry.
 Very close tolerance and better surface finish can be achieved.
 Very fine details can be added to the pattern because pattern will remove by melting.
 The pattern material (wax, mercury) and sprue can be reused.
Disadvantages

 The process is limited by mass and size. Can’t produce heavy casting.
 Difficult to cast that requires cores.
 Time-consuming process. Very long production cycle.

1.3 CO2 MOULDING

Carbon Dioxide Moulding Process:- In CO2 moulding process, moulding sand is mixed with
sodium silicate . The mix is loosely rammed in the mould around the pattern. Carbon dioxide gas
is sent into the mould . carbon dioxide is mixed with sodium silicate and hence silica gel is
formed.

CO2 moulding (Carbon dioxide moulding) is a unique moulding process. This is essentially a
quick moulding process. Here liquid sodium silicate is used as a binder instead of clay in the
conventional sand moulding. The principle behind the CO 2 moulding process is that when CO2
passes through a sand mix containing liquid sodium silicates binder for two-three minutes, it
immediately gets hardened by silica gel formation. The silica gel (SiO 2.x.H2O) is formed by the
chemical reaction between sodium silicate and carbon dioxide. This silica gel gives the strength
sufficient to eliminate baking/ drying of mould.

Figure 2: CO2 molding process

The sand used must be dry and free from clay. GFN of sand grains is in the range of 55 to 85.
The sand is mixed with 3-5% of sodium silicate. Some other additives, such as coal powder,

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wood floor, Dextrin, iron oxide, aluminium oxide etc., are also added to obtain specific
properties. Dextrin, coal powder and wood flour improve collapsibility. Aluminium improves the
hot strength of sand at 800°C. Iron oxide helps to prevent the deformation of cores, and it
produces a smooth interface between mould and metal, thus helping to get a good surface finish.

The gassing of co2 into the mould can be carried out in different ways (gassing with a probe,
gassing with a hood) depending essentially on the mould’s size. The flow rate, time of gassing
and pressure of CO2 gas depends on the depth of penetration required. Usually, gassing time is
within 15 to 30 seconds. The mould must be used within 12hours; otherwise, it starts to absorb
water from the atmosphere and deteriorate.

The chemical for this reaction is given below,

Na2O . mSiO2 . xH2O + CO2 —> Na2CO3 + mSiO2 . xH2O

After passing carbon dioxide, the pattern is removed, and the mould is ready to pour molten
metal immediately into it. This eliminates the headache of foundrymen's need for greater skill
and caring during mould-making and baking.

Applications
 Nowadays, it is used to make cores for conventional mould instead of complete mould.
 Production of heavy and thick-walled steel casting. There is no weight limit.
 Production of cast iron, steel, aluminium, and copper-based alloy casting.  For making
of larger cores of heavy ferrous casting.

Advantages
 Machining allowance can be reduced.
 It has high strength, so it does not require other reinforcement.  Semi-skilled operator is
required compared to dry sand moulding  Process good strength and hardness.
 The process can be mechanized for mass production.
Disadvantages
 CO2 moulding is less suitable for non-ferrous casting and thin-walled casting.
 The life of the mould is short. Mould should use ( can only last ) within 12 to 24hr.
 Poor collapsibility.
 CO2 cores are susceptible to moisture.

1.4 Centrifugal casting

The centrifugal casting method is the method to produce pipes by pouring molten metal into a
rapidly spinning cylindrical mold in which centrifugal force from the rotation exerts pressure on
the molten metal. In 1952, Kubota developed its first centrifugal casting technology for steel.

Centrifugal casting or roto casting is a casting technique that is typically used to cast thin-walled
cylinders. It is typically used to cast materials such as metals, glass, and concrete. A high quality
is attainable by control of metallurgy and crystal structure. Unlike most other casting techniques,
centrifugal casting is chiefly used to manufacture rotationally symmetric stock materials in
standard sizes for further machining, rather than shaped parts tailored to a particular end-use

Typical materials that can be centrifugal cast are metals, cements, concretes, glass, and pottery
materials. Typical metals cast are iron, steel, stainless steels, and alloys of nickel, aluminum, and
copper, magnesium.

Two materials can be combined by introducing a second material during the process. A common
example is cast iron pipe coated on the interior with cement. Working priciple

The centrifugal casting process starts with liquid metal being filled with a hightemperature die
that rotates. The die might be either on a vertical or flat pivot contingent upon the detailed
specifications of the design.

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Figure 3: centrifugal casting

During the process, centrifugal power acts to disseminate the liquid metal in the shape at
pressure moving toward multiple times the power of gravity. This applied pressure ensures that
there are no cracks or other microscopic and macroscopic flaws. This is very similar to the
regular die casting process where applied pressure reduces the overall flaws in the product.

As the die fills, the thicker liquid metal is compelled to the mass of the turning die. Moreover,
directional cementing of sound metal advances from the outer diameter towards the drag, while
the less thick material along with impurities floats to the outer diameter.

Once the solidification is completed, the complete part is taken out from the die and the
remaining debasements in the boundaries of the part are removed through the machining process.
Therefore, you are left with a high-quality material without any internal cavities or air bubbles.

Here’s a simple breakdown of the basic centrifugal casting process when your mold is ready.

 The start is just like any casting process, where you heat the metal beyond its melting
point
  The second step is rotating the mold to prepare it for pouring. Generally, the rate of
rotation is between 300 to 3000 RPM. However, the actual number depends on the
specifics of the project.
 The next step begins with pouring. This is a relatively simple process as it doesn’t require
any special preparation. However, you need to be careful because the process will take
place while the mold is rotating.
 Once the pouring is completed, the next step automatically starts. The rotation facilitates
the cooling process but creates enough pressure within the mold to ensure that there are
no chances of flaws associated with the casting process.
 After cooling, the next step is similar to how any casting process goes. All you need to do
is to remove the mold from the roller and extract the material from the casting.
 Finally, refine the final product. The centrifugal rotation pushes the impurities in the
material to the edges and you can machine them out to get the quality you need.

Types

3 main types of casting methods common throughout the industry.

1. True Centrifugal Casting

The first type, true centrifugal casting is exactly what was described in the previous section. The
process can either be horizontal or vertical. However, horizontal axis rotation produces items like
cylinder liners that have high-intensity applications. Generally, the rotation speed determines the
physical properties like the density and strength of the product in all types. However, the
positioning of the mold and other factors combine to give this centrifugal casting technique the
best overall results.

The true centrifugal process has a lot of advantages over its other alternatives. First and foremost,
the process is miles apart when it comes to mechanical strength and delivers the best-performing
products.

Similarly, you can also remove impurities and other undesirable elements from the product with
common processes like turning on a lathe machine. Apart from that, the entire process is very

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economical and generates minimum scrap while allowing you to create large parts with high
accuracy and relative ease. To sum up, it’s a versatile process with ultra-high reliability that you
can count on.

2. Semi-Centrifugal Casting

The semi-centrifugal casting is very similar to the true process. However, there are some key
differences between both methods and their overall results. First of all, this process delivers a
solid product rather than a tubular cast. Similarly, this casting method also gives you items with
varying densities as the exterior areas of the items you create with this process have a higher
density.

The overall quality of the casting you create is affected by all the factors like the rotational speed,
the overall diameter, pouring temperature, and others. This means that there is a greater risk of
things going wrong, which can naturally affect the quality.

3. Centrifuge Casting

Centrifuging or centrifuge casting is a popular method to create intricate objects with numerous
surface features. Generally, this method is most common for jewelry, small bushes, sleaves, and
other similar products. In centrifuging, you place a mold cavity of a certain shape at a distance
from the rotation axis and continue the process as always. The rotational forces push the molten
metal into the cavity and create the desired shape.

One of the biggest advantages of this casting method is the fact that you can use it for small and
complicated parts without needing any post-processing. Like all kinds of centrifugal casting
processes, the rotation forces keep all impurities near the axis. Since the mold cavity is far from
the center, the product you’ll get will be free from most casting-related flaws.

Applications

• Typical parts made by this process are pipes, flywheels, cylinder liners, and other parts
that are axi-symmetric.
 • It is notably used to cast cylinder liners and sleeve valves for piston engines, parts which
could not be reliably manufactured otherwise.

1.5 Die casting

Die casting is a process that involves melting low melting point metals and injecting them into
already made mold known as die casting mold. A mold or tools come from steel fabricated for a
single project using manufacturing processes such as CNC machining. Consequently, sheet metal
parts fabricated by die casting have high accuracy, precision, and repeatability.

Figure 4: die casting

Types of Die Casting Processes

The two die casting processes used industrially are hot chamber, and cold chamber dies casting.
Each one has its peculiarities and is applicable in different scenarios. Below are what the two
types of processes entail.

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1. Hot Chamber Die Casting

Figure 5: hot chamber die casting

The hot chamber die casting process is the perfect method for working with low melting point
materials such as zinc, tin, lead, and magnesium alloys. It is not suitable for alloys with a higher
melting point as it would damage the pump as the pump would directly contact the metal. It
involves melting the metal and injecting it into the die using pressure from a hydraulic system.
2. Cold Chamber Die Casting

Figure 6: cold chamber die casting

The cold chamber die casting is the perfect method for working with high melting point materials
such as aluminum. This process is ideal for such metals as the high temperature needed to melt
the material can damage the pumping system.
The process involves ladling the melted material into a cold chamber before injection into the
die. The hydraulic system used in a cold chamber process is similar to that of the hot chamber
process. However, it might require a larger pressure ranging from 2000 to 20000 psi.

Steps of Die Casting Process

Whether hot or cold chamber die casting, the standard process involves injecting molten metal
into a die mold under high pressure. Below are the intricate die casting process steps:

Clamping

The first step in die casting is clamping. However, before then, clean the die to remove any
impurities and lubricate the die for better injection and removal of the solidified product. After
cleaning and lubrication, clamp and close the die with high pressure.

Injection

Melt the metal you want to inject and pour it into the shot chamber. The procedure depends on
the process you are using. For example, the shot chamber is cold in the cold chamber die casting,
while it is hot in the hot chamber die casting. After that, inject the metal into the die under high
pressure generated by a hydraulic system.

Cooling

While clamped, allow the metal to cool for solidification. The solidified material will have a
shape similar to the design of the mold.

Ejection

After unclamping the die mold, an ejection mechanism will push the solid casting out of the die.
Ensure proper solidification before ejecting the final product.

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Trimming

This is the final step, and it involves the removal of the excess metal in the sprue and runner
found on the finished product. Trimming is achievable using a trim die, saw, or other procedures.
The removed metal parts are recyclable and reusable in the process.

Applications
1. Manufacture of consumer and industrial products.

2. Manufacture of automotive products.

3. Manufacture of aerospace parts.

Advantages

1. You can create complex parts

2. Manufacture of multiple parts without the need for assembly

3. Lowering labor costs

4. Variable wall thicknesses

5. Tighter tolerances
6. Fast production cycle times

7. Recyclable choice of material

Disadvantages

1. Not suitable for metals with high melting points

2. Not suitable for large sheet metal parts

3. High die cost

4. Long lead time

 1.6 Continuous casting
Continuous casting, also called strand casting, is the process whereby molten metal is solidified
into a "semi-finished" billet, bloom, or slab for subsequent rolling in the finishing mills. Prior to
the introduction of continuous casting in the 1950s, steel was poured into stationary molds to
form ingots. Since then, "continuous casting" has evolved to achieve improved yield, quality,
productivity and cost efficiency. It allows lower-cost production of metal sections with better
quality, due to the inherently lower costs of continuous, standardized production of a product, as
well as providing increased control over the process through automation. This process is used
most frequently to cast steel (in terms of tonnage cast). Aluminium and copper are also
continuously cast.

Range of continuously cast sections

• Casting machines are designated to be billet, bloom, slab or strip casters.

• Slab casters tend to cast sections that are much wider than thick:

• Conventional slabs lie in the range 100–1600 mm wide by 180–250 mm thick and up to
12 m long with conventional casting speeds of up to 1.4 m/minute; however slab widths
and casting speeds are currently increasing.
• Wider slabs are available up to 3250×150 mm
• Thick slabs are available up to 2200×450 mm at a specific steel facility, generically
ranging typically from 200mm to 300mm

Twin-belt continuous casting

Twin-belt continuous casting is a continuous casting process that produces high volume
continuous metal bar or strip of constant rectangular cross section. Twin-belt continuous casting
employs a moving mold consisting of parallel carbon-steel belts held in tension as top and
bottom casting surfaces. Chains of rectangular steel or copper blocks moving with the belts and
spaced according to the desired cast width form the sides of the mold.

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Twin-belt continuous casting is a near net shape casting process, which significantly reduces the
need for secondary rolling or forming operations. For example, when casting copper anode plate
the cast slab is not rolled but rather sheared directly into distinct anode plates.

Advantages

• Ability to cast regular shapes and certain irregular configurations in long tubular form,
which is difficult for other casting methods.
• Continuous cast bars require appreciably less machining stock.
• Continuous cast material is consistently dense and homogeneous in structure, and
therefore well-suited for pressure applications.
• Straight, true, and concentric product for high speed bar machines.

Limitations

• Due to the considerable mold cost and casting machine set-up, it is uneconomical to
consider the continuous cast method for special shapes or special alloys in small
quantities. A customer may need to order over 2,000 pounds of a special size or special
alloy in order to obtain a reasonable cost.

1.7 Counter gravity low pressure casting process

Low-pressure die casting is a method of production that uses pressure – rather than gravity – to
fill molds with molten metal such as aluminum and magnesium. In this process, the holding
furnace is located below the cast and the liquid metal is forced upwards through a riser tube and
into the cavity.
Figure 7: Counter gravity low pressure casting process

In low pressure die casting, the die is filled with metal from a pressurized furnace, with pressures
typically around 0.7 bar. The holding furnace is positioned in the lower part of the vertical die
casting machine, with the molten metal injected upwards directly into the bottom of the mould.

Counter-gravity casting, also called vacuum casting, is a mould filling technique in which low
pressure created inside a mould cavity, causes prevailing atmospheric pressure on the melt
surface to bring about an upward or counter-gravity movement of the melt into the mould cavity.

Sequencing casting

The sequence of the casting operation starts with inserting the dummy bar into the mold to seal
the bottom end. Molten steel is then poured into the mold from the tundish while taking great
care to prevent contact with the air. The withdrawal of the cast strand is started by pulling the
dummy bar downward.

Semisolid processes

Semisolid metal processing (SSM) or thixoforming is a new technology that offers several
advantages over liquid processing and solid processing. This process utilizes semisolid behavior
as well as reduces macro-segregation, porosity, and forming forces during shaping process.

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Semi-solid processing (SSP) is a hybrid between casting and forging. From a design perspective,
its strengths are easily summarized: SSP combines the form freedom of casting with the material
quality of forging, offering rapid production speed and excellent control over tolerances.

Semisolid metal (SSM) processing is a special die casting process, where partially solidified
metal slurry is injected into a die cavity to form die cast components. This article discusses the
flow behavior of an SSM slurry with emphasis on viscosity, rheological behavior, and yield
stress. It illustrates the microstructural formation of semisolids under forced convection. The
article concludes with an illustration that compares two SSM processes, namely, thixocasting and
rheocasting.

1.8 Layout of mechanized foundry

Mechanization of foundry implies use of machines in the foundry to eliminate hardwork.
Theoretically a mechanised foundry should include

1) Sand preparation.

2) Sand handling system.

3) Moulding machines.

4) Mould handling system.

5) Snake out machinery.

6) Fettling or cleaning equipment.

Figure 8: layout of typical mechanization in foundry

Conventionally, however, any mass production foundry using mechanical systems for material
handling is called a mechanized foundry. The order equipment mentioned above is used partly or
fully even in batch production and large jobbing foundries.

Advantages of Foundry Mechanization

The advantages on foundry mechanization include

1) Reduction of manual labour.

2) Use of comparatively less skilled labour.

3) Uniform packing density of moulds.

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4) Lesser rejection of castings.

5) Faster production rate.

6) Low overall cost per piece.

Sand reclamation

Sand reclamation involves physical, chemical, or thermal treatment of sand for reuse in molding
and core-making. There are two major types of systems, mechanical and thermal. A mechanical
system physically breaks down lumps of spent casting sand, into clean sand.

Figure 9: sand reclamation process

Sand reclamation systems. Sand reclamation involves physical, chemical, or thermal treatment of
sand for reuse in molding and core-making. There are two major types of systems, mechanical
and thermal.
 1.9 Material handling in foundry pollution control in foundry
Stationary sources of air pollution emissions in foundry processes, release contaminants into the
atmosphere as particulates, aerosols, vapors, or gases. These emissions are typically controlled to
high efficiencies using a wide range of air pollution control devices. The selection of the
appropriate control technology is determined by the pollutant collected, the stationary source
conditions and the control efficiency required. In some cases, pollutant emissions can be reduced
significantly through process modifications and combustion controls. However, in most
instances, some form of addon pollution control equipment is installed in the ductwork (or flues)
leading to the smoke stack to meet current allowable emission limits. The most commonly used
devices for controlling particulate emissions include;

 Electrostatic precipitators (wet and dry types),

 Fabric filters (also called bag houses),
 Wet scrubbers, and
 Cyclones (or multiclones)

In many cases, more than one of these devices are used in series to obtain desired removal
efficiencies for the contaminants of concern. For example, a cyclone may be used to remove
large particles before a pollutant stream enters a wet scrubber. Common control devices for
gaseous and vapor pollutants include:

 Thermal oxidizers,
 Catalytic reactors,
 Carbon absorbers,  Absorption towers, and  Bio filters.

The following table presents a list of common control devices, the typical contaminates they
Control.

Equipment used for various pollutants

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Common Control Devices

Pollutants

Packed towers, spray chambers, venture Gases, vapors, Sulphur oxides, corrosive scrubbers
acidic or basic gas streams, solid particles, liquid droplets
Carbon absorbers Vapor-phase volatile organic compounds
(VOCs), hazardous air pollutants (HAPs)
Fabric filters or bag houses Particulate matter (PM)
Catalytic reactors, catalysts VOCs, gases
Cyclones Large PM
Electrostatic precipitators (ESPs) PM
Incinerators, thermal oxidizers, after VOCs, gases, fumes, hazardous organics,
burners odors, PM
Bio filters VOCs, odors, hydrogen sulfide (H2S),
mercaptans (organic sulfides)

1.10. Computer aided design in casting process

The method layout of a casting is an important aspect of tooling development. It involves
decisions
regarding part orientation in mold, parting line, cores, cavity layout, feeders, feedaids and
gating system. An improper method layout leads to either poor
quality or low yield, affecting manufacturing costs and productivity
The method layout of a casting is an important aspect of tooling development. It involves
decisions regarding part orientation in mold, parting line, cores, cavity layout, feeders, feed aids
and gating system. An improper method layout leads to either poor quality or low yield, affecting
manufacturing costs and productivity.

Computer-aided Method Design

The main input is the 3D CAD model of an as-cast part (without drilled holes, and with draft,
shrinkage and machining allowance). The model file can be obtained from the OEM firm, or
created
by a local CAD agency. Various display options such as pan, zoom, rotate, transparency, and
measure are provided to view and understand the part model (Fig.1). The cast metal and process
are selected from a database. Part thickness distribution is displayed for verifying the model and
evaluating partprocess compatibility
The main input is the 3D CAD model of an as-cast part (without drilled holes, and with draft,
shrinkage and machining allowance). The model file can be obtained from the OEM firm, or
created by a local CAD agency. Various display options such as pan, zoom, rotate, transparency,
and measure are provided to view and understand the part model .The cast metal and process are
selected from a database. Part thickness distribution is displayed for verifying the model and
evaluating part-process compatibility.

The method design involves cores, feeders and gating system. Holes in the part model are
automatically identified for core design. Even intricate holes can be identified by specifying their
openings. The print length is computed based on the core diameter and length (the user can
change these if required), and the entire core model is automatically created. The program
suggests the number of cavities depending on the mold size (selected from a foundry-specific
library), considering both cavity-cavity and cavity-wall gaps. Then the part model is
automatically duplicated in the correct locations as per the desired cavity layout. To facilitate
feeder location, the program carries out a quick solidification analysis and identifies feeding
zones. The user selects a suitable location close the largest feeding zone, and the program

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automatically computes the dimensions of the feeder using modulus principle (solidification time
of feeder slightly more than that of the feeding zone). The feeder model is automatically created;
the user can change its dimensions or apply feed-aids such as insulating sleeves and exothermic
covers. More feeders can be created by specifying their positions. The gating channels are
created semi-automatically. First, the user indicates gate positions on the part or feeder model.
Then the sprue position is decided, and it is connected to the gates through runners. Runner
extensions are automatically created. Any type of gating system: horizontal, vertical, investment
tree, and direct pouring can be created or modified within minutes. The program also suggests a
suitable filling time (which can be changed by the user), accordingly computes the dimensions of
the gating channels, and creates their solid model.
The method design involves cores, feeders and gating system (Fig.3). Holes in the part model are
automatically identified for core design. Even intricate holes can be identified by specifying their
openings. The print length is computed based on the core diameter and length (the user can
change
these if required), and the entire core model is automatically created. The program suggests the
number of cavities depending on the mold size (selected from a foundry-specific library),
considering
both cavity-cavity and cavity-wall gaps. Then the part model is automatically duplicated in the
correct locations as per the desired cavity layout.

To facilitate feeder location, the program carries out a quick solidification analysis and identifies
feeding zones. The user selects a suitable location close the largest feeding zone, and the
program
automatically computes the dimensions of the feeder using modulus principle
(solidification time of
feeder slightly more than that of the feeding zone). The feeder model is automatically created;
the user
REFERENCE

References
studocu . (2019, 06 4). Retrieved from studocu website: https://www.studocu,com

Sahoo, M., Rao, T. V. R., & Elangovan, M. (2013). Principles of Metal Casting. CRC
Press

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Tutorial questions and answers

Section 1 mcq
1) Machined surfaces on the pattern are marked by:
1: Blue color
2: Red color
3: Green color
4: Black color
Ans: (2)

2) Which of the following is used as a binder in the core?

1: Linseed oil
2. Green sand

3. Wood

4. None of the above

Ans: (1)

3) Linseed oil is used as a ____ in the core sand.

1: Flux
2: Lubricant
3: Binder
4: None of the above
Ans: (3)

4) Slick is used to ____.

1: repair corners in the mould
2: to ram the sand
3: to scoop sand deep in the mould
4: none of the above
Ans: (1)
 5) In which of the following moulding, will you use match plate pattern?
1: pit moulding
2: bench moulding
3: machine moulding
4: green sand moulding
Ans: (3)

SECTION 2 foundry layout

This set of Foundry Multiple Choice Questions & Answers (MCQs) focuses on “Principles of
Foundry”.

1. _____________ is a process of preparing a casting.

a) Founding
b) Forging
c) Melting
d) Pouring
Answer A
2. Which of the following is prepared using pattern is foundry?
a) Mould
b) Sand
c) Core
d) Mould, Sand and Core
Answer D
3. Fettling is the last step of the foundry.
a) True
b) False
Answer A
4. Which of the following metal castings are used to make casting in the foundry?
a) Brass
b) Aluminum
c) Iron
d) Brass, Aluminum and Iron
Answer D
5. To form castings, always virgin metal is used in foundries.
a) True
b) False
Answer B
6. _________ tuyeres increase the melting efficiency.
a) Single
b) Double
c) Auxiliary

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d) Blast
Answer C
7. The foundry uses ___________ process to relieve stresses produced in castings.
a) Reforming
b) Heat treatment
c) Water treatment
d) Cooling
Answer B