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Molding by Shell, Die & Investment Casting: 08120033 08120009 08120021 Metallurgy 6 Semester
Molding by Shell, Die & Investment Casting: 08120033 08120009 08120021 Metallurgy 6 Semester
Molding by Shell, Die & Investment Casting: 08120033 08120009 08120021 Metallurgy 6 Semester
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Shell molding
Casting process in which the mold is a thin shell (typically 3/8 inch) made of sand held together by a thermosetting binder (risen). The process of creating a shell mold : Fine silica sand ,covered in a thin (36%) thermosetting resin and liquid catalyst is dumped, blown, or shot onto a hot pattern. The pattern made of cast iron is heated to 230 to 315 C (450 to 600 F). The sand is allowed to sit on the pattern for a few minutes to allow the sand to partially cure. The pattern and shell together are placed in an oven to finish curing the sand. The hardened shell is then stripped from the pattern. For casting the shell mold is placed inside a flask and surrounded with shot, sand, or gravel to reinforce the shell.
The machine that is used for this process is called a shell molding machine. It heats the pattern, applies the sand mixture, and bakes the shell.
Advantages:
Higher production rate than sand casting High dimensional accuracy and smooth finish Amenable towards automation Thin sections can be cast
Limitations: Requires expensive metal patterns resin adds to cost part size is limited Highly complicated cannot be made
Common metals:
Cast irons, casting alloys of aluminum and copper
Materials normally cast in permanent molds Al. alloys Mg alloys Zn alloys Grey Cast Iron
Cast products
The basic idea is to force metal into a permanent mold using high pressure. The metal then cools (often assisted by water cooling of the die). The mold is then opened, and the casting is ejected.
Constructed of alloy steel in two pieces (called the cover and the ejector). The die must withstand high temperature and pressure, so the die is typically made for chromium or tungsten steel alloys.
Molten metal enters the die cavity at pressures 70 to 2000 times the normal atmospheric pressure
Employment of high pressure aids in die casting of Narrow sections Complex shapes Finer surface details
Hot chamber machines are: -good for low temperature zinc alloys (approx. 400C) - cycle times must be short to minimize metal contamination - metal starts in a heated cylinder - a piston forces metal into the die - the piston retracts, and draws metal in Cold chamber machines: - casts high melting point metals (>600C) - high pressures used - metal is heated in a separate crucible - metal is ladled into a cold chamber - the metal is rapidly forced into the mold before it cools
Horizontal Type
Cold chamber die casting suitable for casting of Mg alloys Brass Aluminum alloy Pressure applied in cold chamber die casting method can be as high as 2000 atmospheres
Advantages
Applications: - automotive parts - appliances - office machines - bathroom fixtures - outboard motors
Die closed and plunger withdrawn Metal forced into die cavity at fixed press. Plunger withdrawn & die opened
Limitations
Only low melting alloys (such as Zn, Sn, Pb) are cast
Small castings weighing less than 4.5 kg can be cast
Intricate shaped objects like jewelry Cylinder heads cam shafts gas turbine blades
Advantages of Investment Casting Process Complicated and intricate shaped products can be easily cast High dimensional tolerance achievable Surface finish is excellent Additional machining not required as it is a net shape process All types of metals and alloys can be cast by this process
Common metals: Mainly aluminum, copper and steel; also used with stainless steel, nickel, magnesium and precious metals Limitations
Size of the casting is limited (max. around 5 kg) A relatively expensive process
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