8/27/2020

Introduction to Casting
Casting and Joining Processes
ME 251

Akash V. Vyas
Assistant Professor
(Mechanical Department- CSPIT)

Definition
METAL CASTING is the process
of
producing metal/alloy components
of
desired shape & size
by
pouring of liquid molten metal/alloy in prepared mould (of that
same shape)
&
then allowing the metal/alloy to cool or solidify.
Solidified piece of metal/alloy is also known as CASTING.

The term Casting is : Verb (process) | Noun (product)

2
Akash Vyas, CSPIT, CHARUSAT

1
 8/27/2020

History : Metal Casting in Ancient and

Medieval Times

Rigved mentions casting equipment:

dhamatri (cupola), bhastri (blower)

Pillar of Ashoka
made up of cast iron Cast bronze dancing girl,
Mohenjo-daro, 3000 BC. 3
Akash Vyas, CSPIT, CHARUSAT

History: Bronze Castings – India

4th Century AD 5th Century AD 6th Century AD 9th Century AD

Bodhi Budhha Nataraja Krishna

Stupa (Gupta Period) (Chola Period) (Chola Period)

2
 8/27/2020

History: Bronze Castings – India

11th Century AD 12th Century AD 18th Century AD

Lokanatha Subrahmanya Shiva & Parvati

(Ramapala period) (Chola Period)

History: Bronze Castings – Asia and Middle East

3000 BC 5th Century BC 16th Century AD

Frog Cat, Buddha Seated Buddha

(Middle East) (China) (Thailand)

3
 8/27/2020

History: Bronze Castings – Europe

Thinker by
Auguste Rodin
[1840-1917]

Gates of Hell

History: Industrial Foundries – Europe

Whitechapel Bell Foundry, UK

Liberty Bell,
Philadelphia

4
 8/27/2020

Steps involved in making a casting

1. Make the pattern out of Wood , Metal or Plastic.
2. Prepare the necessary sand mixtures for mould and core
making.
3. Prepare the Mould and necessary Cores.
4. Melt the metal/alloy to be cast.
5. Pour the molten metal/alloy into mould and remove the
casting from the mould after the metal solidifies.
6. Fettling. (Cutting of feeders, gates, sprue)
7. Clean and finish the casting.
8. Test and inspect the casting.
9. Remove the defects, if any.
10. Relieve the casting stresses by Heat Treatment.
11. Again inspect the casting.
12. The casting is ready for painting, shipping and dispatch.
9
Akash Vyas, CSPIT, CHARUSAT

Sand Casting Process

Terms used in sand casting process

Cut section of sand mould box

10
Akash Vyas, CSPIT, CHARUSAT

5
 8/27/2020

Foundry
Commercial setup for manufacturing of casting.
Categorized as follow.
▪ Captive Foundry
▪ Jobbing Foundry
▪ Production Foundry
▪ Semi Production Foundry
May also be classified as
▪ Ferrous Foundry
▪ Non Ferrous Foundry
A man who works in a foundry
Iron Foundry, Railways Workshop,
is called as foundrymen. Jamalpur, W. Bengal [1897]
11
Akash Vyas, CSPIT, CHARUSAT

Sand Casting Foundry: Moulding Line

12
Akash Vyas, CSPIT, CHARUSAT

6
 8/27/2020

Sand Casting Foundry: Metal Melting

13
Akash Vyas, CSPIT, CHARUSAT

Sand Casting Foundry: Metal Tapping

14
Akash Vyas, CSPIT, CHARUSAT

7
 8/27/2020

Sand Casting Foundry: Metal Pouring

15
Akash Vyas, CSPIT, CHARUSAT

Sand Casting Foundry: Fettling

16
Akash Vyas, CSPIT, CHARUSAT

8
 8/27/2020

• Advantages of Casting

Freedom of Design • Disadvantages/Limitations

(Shape, Size & Quality)
of Casting
Cast as One Piece Less Wastage Labour Intensive Process
(Eliminates joining) (Zero type process) (Skilled manpower required)

Complex Shapes
Safety Matters First
(Shapes that can’t be machined /
(Handling of molten metal)
Internal hollow features)

No Barrier of Size & Weight Poor Surface Finish

(From few grams to large tones ) (In case of sand casting)

Cheaper Process
(Inexpensive tools/materials)
17
Akash Vyas, CSPIT, CHARUSAT

Casting Applications

Transport Sector
Industrial Machinery
Other Sectors
Value Addition

9
 8/27/2020

Casting Applications – Automobile

Wheel Rim Manifold Pipe Radiator part

(Al-alloy) (Al-alloy) (Cast Iron/Brass)

Cylinder Block Differential Casing Gear Case Housing

(Cast Iron) (Ductile Iron) (Cast Iron)

Casting Applications – Railways & Shipping

Rail Engine Frame Bogie Frame Railway plate

(Alloy steel) (Ductile Iron) (Alloy steel)

Ship Anchor Fitting Ship Fitting Bollard

(Cast Iron) (Ductile Iron) (Ductile Iron)

10
 8/27/2020

Casting Applications – Aerospace

Engine Fuel Pump Engine Part Chassis part Chassis part

(Al-alloy) (Cu-alloy) (Ti-Al alloy) (Ti-Al alloy)

Impellor Fuel Pump Mounting Coupling part Brake Mounting

(Al-alloy) (Mg alloy) (Mg-alloy) (Ti-Al alloy)

Casting Applications – Defence

Tank Pump Head Tank Tracks Ice Cleat Fire Suppression Housing
(Cast Iron) (Cast Steel) (Brass)

Cannon Cannon Fitting Tank Fittings Ammunition Box

(Bronze) (Brass) (Al-alloy) (Al-alloy)

11
 8/27/2020

Casting Applications – Sanitary

Fitting Pipes Ball Valve Soil Pipe Fittings Valve

(Brass) (Cast Iron) (Ductile Iron) (Cast Iron)

Pipe Splitter Large Pipe Manhole Cover

(Cast Iron) (Cast Iron) (Cast Iron)

Casting Applications – Machine Tools

Compressor Case Hand Wheel Spanners

(Cast Iron) (Cast Iron) (Brass/ Cu Alloys)

Shaft Housing Coupling part Frame Housing

(Cast Iron) (Ductile Iron) (Al Alloy)

12
 8/27/2020

Casting Applications – Electrical & Energy

Motor Casing Generator Housing Switch Gear Housing

(Cast Iron) (Cast Iron) (Al alloy)

Compressor Case Pedestal of Wind-turbine Windmill hub

(Cast Iron) (SG Iron) (SG Iron)

Casting Applications – Industrial Machinery

Cement Plant: Kiln Head Chemical Plant: Steel Plant: Roll

(Cast Iron) Volute Pump(Alloy Steel) (Steel)

Power Plant: Impeller Paper/Sugar Plant: Textile Plant:

(Cast Iron) Mill Headstock (Cast Iron) Roll Cams (Ductile Iron)

13
 8/27/2020

Casting Applications – Construction Equipment

Pivot Pin for bulldozer Bowl of Crusher Bucket Pin

(Alloy Steel) (Cast Iron) (Alloy Steel)

Drive Spindle assembly Surface Boxes Ball Socket/Cap

(Cast Iron) (Cast Iron) (Alloy Steel)

Casting Applications – Farming and Mining

Auger Deep Plough Shovel Bucket Loader

(Cast Iron) (Cast Iron) (Ductile Iron) (Cast Iron)

Toothed Wheel Lenker Paddy Thrasher

(Cast Iron) (Cast Iron) (Cast Iron)

14
 8/27/2020

Casting Applications – Biomedical Implants

Tooth implants Knee Implant Hip Joint

(Ti Alloys) (Ti-Co alloy) (Ti-Co alloy)

Hip Joint Shoulder Joint Oral Implants

(Stainless Steel) (Ti-Alloys) (Ti-Alloys)

Casting Applications – Art, Deco, Jewellery

Door castings Furniture Bathroom Fitting Garden Sculpture

(Bronze) (Cast Iron) (Zinc Alloy) (Cast Iron)

Jewelry / Ornaments Bell Casting Monument Horse

(Gold) (Bronze) (Bronze) (Bronze)

15
 8/27/2020

India - A Vision for the New Millennium

Dr. A.P.J. Abdul Kalam
Former President of India

“By 2020 India will be a leading producer of quality castings…

and will be a large exporter of these items…

In the foundry sector, the increased accent has to be on control of

dimensions/surface finish, value addition through machined casting,
mechanization and automation with increased scale of production…

We need to develop better tooling capabilities (using) CAD.”

Akash Vyas, CSPIT, CHARUSAT

16